(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2008/0110577 A1
`Winsness
`(43) Pub. Date:
`May 15, 2008
`
`US 200801 l0577Al
`
`(54)
`
`lVIE'l‘HOD AND SYSTENIS FOR ENHANCING
`OIL RECOVERY FROM ETHANOL
`PRODUCTION BYPRODUCTS
`
`lnve11tor:
`
`(76)
`
`David J. Winsness, Alpharetta, GA
`0J3)
`
`Correspondence Address:
`KING & SCHICKLI, PLLC
`247 NORTH BROADVVAY
`LEXINGTON, KY 40507
`
`(21)
`
`Appl. No.:
`
`11/856,150
`
`(22)
`
`Filed:
`
`Sep. 17, 2007
`
`(63)
`
`Related U.S. Application Data
`PCT/US2006/
`
`Continuation of application No.
`009238, filed on Mar. 15, 2005.
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`(2006.01)
`BIIID 1/22
`(2006.01)
`B01D 21/26
`(52) U.S. Cl.
`............................. .. 159/5; 494/37; 159/473
`(57)
`ABSTRACT
`in one aspect of the invention, a method and related system
`efliciently and effectively recover a significant amount of
`Valuable, useable oil from byproducts formed during a dry
`milling process used for producing ethanol. The method may
`include forming a concentrate fron1 the byproduct and recov-
`cring oil from the concentrate. The step of forming the con-
`centrate may comprise evaporating the byproduct using a
`multi-stage evaporator, as well as recovering the oil before the
`final stage ofthe evaporator. Further, the step ofrecovering oil
`from the concentrate may comprise using a centrifuge and, in
`particular, a disk stack centrifuge. Other aspects of the inven-
`tion include related methods and subsystems for recovering
`oil.
`
`3
`
`Whole Sti|lage_
`"Mechanical Separallun"
`Mnlsiure Conlztil of Distillers Wet Gralns:
`Sullds concommllnri ln Thin SHIIEQE‘.
`Moisture Cnnnenlratlan In syrup:
`GPM
`145
`m
`27
`
`Tutal capacity
`--rm: Muistum
`.-ma: Sollrls
`
`Lbs/Hr
`72.21"
`5ii.7n2
`15.501
`
`CASE 1
`"BEFORE"
`65.0%
`
`6.79%
`
`110.0%
`
`Thifl Smlfige
`
`Total Volume
`Muisturez
`Solidi:
`all content:
`
`GFM
`87.5
`ans
`5.9
`1.1
`
`Lbslhr
`43.575
`-ll!,l!!'lD
`2.020
`566
`
`%
`um
`6.70 /.
`1.:I'/2
`
`%
`
`Dlstlllers Wel Grains
`Lbslhr
`GPM
`Total Volume
`515
`28,634
`,,,,,,,,,m:
`11,.
`‘mm
`
`mni Sullltl
`mt
`10.022
`
`
`
`
`
`
`Evaporator Removes
`26,146
`Lbslhr afwaler. or
`53
`GPM arwater
`55033
`opmisng Cast tilhr)
`
`Syrup
`GPM
`Lain
`Zr:
`Total Volume
`35.0
`17.430
`Molslurn:
`213.9
`13,911
`80.0%
`
`
`
`
`1,1 566GI! cnnium: 32'1-
`
`17%
`5!
`L320
`Solids:
`
`
`
`
`
`
`Dried Pt‘£7dIll:t~ liavlng 10'/1 rnnlslure cantenl [lbslhr]:
`31,055
`Mcilslure ta Evapmato (lbsi’hI)t
`
`sz.-a
`an In GFM:
`52.4
`
`Fuel Riaqulrafl in Dryer (in Dacathormsj:
`
`
`5262.22
`Dryar Opzrallng cost @ 55.00 Decatnemi (SIhr}:
`5300. 35
`Froduizlvalue .'5Ihr):
`I
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication May 15, 2008 Sheet 1 of ll
`
`US 2008/0110577 Al
`
`CASE
`"BEFORE"
`65.0’/u
`6.70"/o
`
`
`
`
`
`Whole Stillage
`"Mechanical Searation"
`Mnlstura Content of Distillers Wat Grains:
`Snllds Concentration in Thin Stillage:
`
`Moisture Concentration In Syrup:
`
`
`
`
`
`
`Total Capacity
`5fl,‘l'IJ2
`11B
`-Tntai Moisture
`
`-Total Sallds 13.503 27
`
`
`
`
`
`Thin Stillage
`
`%
`slhr
`grin
`43.576
`37.5
`Total Volume
`aw.
`4o.u9n
`50.5
`Moisture:
`1.1%
`566
`1.1
`all content:
`
`Solids: 6.70!’ 5.5 2.920
`
`
`
`Distillers Wet Grains
`
`gm
`Lhslhr
`%
`
`57.5
`23,634
`:7 4
`18,612
`65.0%
`
`201
`
`
`
`Total Volume
`Mulslumz
`
`Tuinlsullda
`
`
`
`
`
`
`
`Evaporator Removes.
`
`Lbslhr nl’ Water. or
`26,146
`GFM of Water
`53
`55033
`Operating Cost mhr}
`
`
`
`
`
`Syrup
`Total Volume
`Mulslurn:
`Oll Cunlont:
`sufilds:
`
`M l-Iii"
`35.0
`17,430
`2a.u
`13.944
`1.1
`566
`5,9
`2,520
`
`°_/2
`80.0%
`3.2%
`17'/.
`
`Fig. 1
`
`
`
`Drlad Prac1ui:t- havlng 10% mulsture content (|bsl|1r):
`Malslure Io Evaporaie ttbslhr-3:
`or, In GFM:
`
`
`Fuel Required In Dryer (in Decatherms):
`Dryer Operating Cast @ $5.00 Decatherm ($I|1r}:
`
`Product Value $Fhr}:
`
`
`15,009
`31.055
`52.4
`
`52.4
`
`$252.22
`
`5590.36
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication May 15, 2008 Sheet 2 of 11
`
`US 2008/0110577 A1
`
`Whole Stillage
`“Mechanma|Separafiun"
`Mnlslune Content of Dlsllllurs Wet Gmlns:
`Snllds Cuncanlrallun in Thin Slillagaz
`Mnlslux-2 Bunoanlratlun In 5 ru :
`
` CASE 1
`"AFTER"
`a5.nll
`6,70%
`
`
`
`
`
`
`Tnml Capacity
`- Total Nlalslur:
`
`-1013! Solid:
`
`
`
`
`Distillers Wet Grains
`
`
`M mm:
`"A
`
`Total Vnlume
`57.5
`28,634
`37.4
`13,612
`6 5.0%
`Mulslum
`
`201
`Tnlnl snmn
`
`
`
`Thin Slillage
`
`Total Volume
`Mnlsturu:
`ml Canlenlz
`Svlldsz
`
`§P_M
`B'.’.5
`50.5
`1.1
`53
`
`mm
`43.575
`40.090
`SEE
`1.220
`
`25
`327-
`1.3%
`6.70%
`
`
`
`Evaporator Removes
`
`Lbslhr cl Waler. or
`25,143
`GPM ufwaler
`53
`$5D_QB
`Dpnrallng Cusl l$.ll1r]
`
`
`
`
`
`
`
`
`Syrup
`gm Q E
`
`Total Volume
`35.0
`17.430
`Mulsturul
`25.0
`13.514!
`80.0%
`Clll Cunlunl:
`1.1
`555
`117:
`5.3
`2.520
`17%
`
`
`
`
`SIIIHI Cnllllnllllllilhll:
`
`
`Lam:
`533
`
`GFM
`1.1
`
`
`
`Dll Recovered llaslhr :
`Oil Value $Ihr :
`
`$102
`
`
`
`
`
`Drlad Pmducl - having 10'']: mnlsture eonlnnt fibslhr):
`
`Molslure In Evaporatu llhslhr):
`or, In GPM:
`Fuel Requlrenl in Dryer (In Decalharms):
`
`Dryer Operating Cost @ $5.00 Dacitlmrm ($I'hr]:
`Pruducl Value lflhrl:
`
`
`
`Fig. 2
`
`14.411
`
`31.115
`
`82.5
`52.5
`
`$262.73
`$576.45
`
`
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication May 15, 2008 Sheet 3 of 11
`
`US 2008/0110577 A]
`
`
`
`
`Whole Slillage
`"Mechanical Searatlon"
`Molslure ccmtanl of Distillers Wet Gralns:
`Sollds Cunceniraliun In Thln Stillaga:
`Mulslura Cnncanlrallnn In Syrup:
`GFM
`145
`11 E
`
`
`
`
`Tulal Capacity
`- ‘lolal Mnlstura
`- Total Snllds
`
`
`
`Lbs./HI‘
`72.210
`53,702
`
`Distillers Wet Grains
`
`
`gm
`Lhslhr
`1:,
`E Lhslhr
`E
`Total Volume
`56.9
`28,325
`Total Volume
`83.1
`431355
`
`
`Molsluw:
`34.1
`15.955
`50.0%
`museum:
`33.7
`-H.707
`95%
`
`
`Tulil Suflnls
`22.8
`on Gnnlnnl:
`1.1
`566
`1.3‘/.
`
`
`12
` 1,512
`
`
`
`
`Thin Slitlage
`
`
`
`
`
`
`
`%
`Lbslm;
`G_F'_lgl_
`ymp
`5,445
`10.9
`Total Volume
`.
`Mnlsturu:
`
`01! Cul1|l!MI
`Sulldst
`
`Evaporatnr Flernnues
`33,440
`Lbsfhr of Water, or
`T7
`GPM of Waller
`$7‘4_95
`Operating Cost {Sim}
`
`
`
`S
`
`
`
`Drled Product — havll-:g1ll"/a moisture content (Eb5.'hr):
`15,909
`
`
`
`Mnlslunz to Evapuralu (lbslhrlz
`13,761
`or. In GPM:
`37.’!
`
`31.7
`Fuel Requlred In Dryerlln Denalherms):
`
`
`
`Dryer Operafing Cast @ 55.00 Decalherm (5/hr):
`$158.41
`
`Product Val-ua lslhrlz
`$509.35
`
`
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication May 15, 2008 Sheet 4 of ll
`
`US 2008/0110577 Al
`
`
` Whole Stillage
`"Mechanical Separation"
`"AFTER"
`Molsture content at Dlsllllars Wat Gralns:
`liu.ll%
`
`Sullds Cunuanlrallon In Thln Stlllaga:
`3.67%
`Molstum concantratlan in 5 ru:
`
`GPM
`Lbstflr
`145
`72,210
`Total Capacity
`—Talnl Mulslura
`i1!
`58,702
`-Tulil Solids
`27
`13,508
`
`
`
`
`
`
`
`“£9
`95'!-
`
`Distillers Wet Grains
`
`Qgfl
`_Gfll_
`“A
`Lbslhr
`£5__l3_M
`43,885
`88.1
`Total Volume
`28.325
`56.9
`Total Volu me
`
`41.7n7
`33.7
`60.0%
`Mulslum:
`15.955
`34.1
`Malslnm:
`
`EBG
`1.1
`Tuul sand:
`22.8
`Ell Content:
`
`
` 3.2
`1,512
`
`Thin Stillage
`
`
`
`
`Evaporator Removes
`38,4-40
`Lbs/hr ol Water, or
`77
`GFM afwaler
`$7436
`
`Dpurnllng cast (inn)
`
`Total Volume
`Mulalurnt
`Clll Gonlanl:
`
`5 mp lbslhr:
`4 907
`
`Mulslwn:
`85.67.
`Mnlstum llbsnirl:
`3.25?
`
`Dllcunlnllltllafllr)‘.
`Ill
`Einllfll l:orIlenl[1l:alm}:
`1.612
`
`
`
`
`
`
`
`DII Recovered lbslhr :
`Oilvalue $Ii1r:
`
`
`
`Fig. 4
`
`14.411
`Dried Product - havlng 10% mnlstura content tlbslhr]:
`
`
`Malsture to Evaporala llbslh r):
`18.821
`
`
`or. in GFM:
`37.8
`
`
`Fuel Requlmd in Dryer (In Decalherms):
`31.5
`Dryer Operating Cost @ $5.00 Dacathenn (SIN):
`$1 58.92
`Product Value ($Ihr):
`$576.45
`
`
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication M
`
`
`'< —L U]
`
`2008 Sheet 5 of 11
`
`US 2008/0110577 A]
`
`lbslhr
`200.000
`4.EDO
`
`RAW MATERIAL
`
`50 mmgy Ethanol Plant 32.520
`162,550
`
`1
`
`2 Phase Decanter
`'
`l_..—.
`
`Dlstillars Wat Grains
`Call
`5 0/.
`Salids
`31 5%
`flaiar
`51.n-/.
`
`Ihslhr
`61,641
`3,346
`23, ‘£60
`35 I36
`
`Ibslhr
`
`lbsfhr
`\
` ‘I38 359
`
`
`
`Cnnnanlralnfl Ellllngn
`on
`em
`Sullds
`2fi.|1!i
`waiar
`mu-.4
`1
`J 4
`1 Camrlfugu
`| L ,.r-"‘
`
`"' ‘—‘ Q
` Wat Grains + Syrup 1
`
`Suipnlldnd sand;
`sands
`.m.n-/.
`Waler
`mu-:5
`
`4,7au
`
`mm
`3,153
`
`l|:|sJl1I
`1 309
`
`my
`
`5'43"” 7'3
`filfll 5-I
`
`$1,:-um
`
`§_9rn DH
`
`43.177
`
`‘ Walar Evauumted
`lbsihr
`
` l
`
`npermnuc ::as'rs
`mu Rnquimd By E|rynr(E|um:|hnrlnI)
`Dpnmllng Cnsl Inf hnur||551Da!:a1lIflM\
`nu-vn ruquirl.-d by Dealnlnr : and CanIn"LI_-13
`Dpnrmlna Cnil par hnuv ll §.|154'XWH
`Fun! Ruquamu H)'EIII!'pIII1![‘r[DuEIUIummj
`Opwmlna Cml pIxhnurn( sammnmm
`Tnlillfinlr-nflna I:=I (sum
`
`7a.u
`341.0
`liEI.l
`
`itln
`
`5301.75
`517.05
`nu
`sun:
`
`mm;
`15251.1
`man
`
`Pmmc: Vnllm
`nuns gcupuw,-1
`Vnhmfl III ITWWH
`Cum on {camzm
`VIIILIIILI ll Slflflllhn
`
`man Vnmn who
`
`Ibsrhr
`Cnnnunlralnd suuagu
`12,904
`
`
`011
`1.1%
`145.4
`
` Sulmls
`Walar
`
`
`
`Eu-aoralur ll
`Wnlar Evanarulefl
`
`lbslhr
`19 014
`
`;
`
`Ibslhr
`Evagorator I
`
`101.575
`Water Eva an-Bled
`1
`
`Ibslhr
`36,381
`1454.-I
`9.460
`25 456
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication
`
`
`
`y 15, 2008 Sheet 6 of 11
`
`US 2008/0110577 A1
`
`50 mmgy Ethanol Plant
`
`abs/hr
`RAW MATERIAL
`200,009
`Oll
`4,300
`nu.
`
`Snflds
`32,620
`15 35:.
`Walar
`152,5au
`Mam
`
`
`3Fha5aDe|:anter
`1
`’ b ,/|/ 51';.,.
`
`
`
`Wash Wahr
`"Law Dll CwnlIml'
`
`Ibslhr
`
`
`
`53 571‘
`
`\ lbslh r
`{nm1u..u..uu
`
`77 4'71
`
`..........................
`- -> Wash Walur Ralurn
`
`II
`
`I
`|
`I
`I
`I
`E
`I
`
`Distlllnrs Wul Grains
`5.4%
`mu-:5
`
`lbslhr
`135,511
`Wat Grains * Wash Water
`3,345
`OI]
`2155:.
`23.160
`Sullds
`17.151.
`109,105
`Water
`ausm.
`2 PhaseDecanter
`1
`Ibslhr
`washed "Wat Grams"
`
`on
`3.2;-.
`1,540
`Sailds
`1!-D15
`
`
`WEIEF
`57.05’:
`
`
`
`18
`
`
`
`
`Ihslhr
`
`in Stillag
`141,350
`Oil
`2.1%
`2,959.5
`Sulids
`615:.
`5.460
`Wuler
`91.2%
`129 440
`I / I Z’
`r
`
`a; Evaorator
`Ibsfhr
`n .
`
`1 l
`
`I
`Ihsthr
`Gunauntmmi sullnuu
`41,399
`
`0|]
`2959.9
`7.1%
`
`Snlids
`9.45”
`nu‘/I.
`28 5:75
`mm
`Walar
`
`
`
`
`
`We! Grains + syrup2.I'.i Fig. 6
`
`‘tr
`J
`
`lhslhr
`
`Corn CHI
`
`lbflhf
`2 E54
`
`
`
`
`Pmducl Valun
`was [Gnpndtfl
`Vmuai nl I'll]/Inn
`cm on (unpnnm
`Vnlund ul slullnnn
`
`TuI1II\lI|I.Ia(SIHI1
`
`Jhfifln‘
`:I777l.|.3
`:5a3.9
`
`Eflr
`51.12224
`Egmajl
`
`Iflu
`5409,21
`315.65
`5153.5
`
`59.9
`an m
`555
`
`QEEFIATING GO5T§
`Fuul Rtrquland By Dryer [|2|nI::mom\5)
`Unurnllnu Bnst;::Ir|'.BurnL55lDm:nUImu
`KWH vmwlrvri hy n..u..I..r I .1 u nnd Cnntrfluua
`Upnmlinu Gnu pL:rhnura'. E.D5lKWH
`Funl Ranulmd By Evnpwulur [E‘lm:1Inunn5]
`Cl|1I:mllng EH5! par hm.-ml §5lDBEnlJ\Bn'Tl
`Tlllllflpllrnlllvg Call. |$llIr}
`
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication
`
`
`
`y 15, 2008 Sheet 7 of II
`
`US 2008/0110577 A1
`
`50 mmgy Ethanol Plant
`
`
`
`Dneunlarluqulzt
`
`lbs/hr
`‘IJIISEEJ
`
`\
`a-=-um |JI1I-Id
`
`ihalhr
`RAW MATERIAL
`200,000
`Du
`4.E0fl
`2,454
`
`Sands
`32520
`11315
`162.530
`
`
`
`
`
`Wash Walar
`73,970_]
`5
`Ibslhr
`
`-
`-------"-"--'---------3
`51,541
`Dlsllllnrs Wat Grain:
`3.345
`OII
`5 4%
`Sulids
`37.5%
`23.130
`— -5 Wash Walar Rolum
`77;41I
`ernm
`as 136
`I
`Water
`
`,
`1.
`lbslhr
`|
`lbslhr _
`We! Gralns + Wash Water
`135,611
`1
`Thin Slillaga
`141,560
`25-/.
`|
`3,346
`2.559.!
`DH
`OH
`Su|Ids
`17.131.
`23.160
`I
`Snllds
`5,450
`Waiar
`505%
`109 105
`I
`Waller
`125,440
`1
`2 Phase Decanter
`
`II15Ihr
`64,389
`
`lbsih1'
`2.564
`
`§J_h_[
`smuu
`jmjg
`
`SI‘1'l1.|Il
`
`
`
`2-1%
`6.7%
`91.1%
`
`
`
`III
`
`Ibsmr
`H10 461
`
`7
`
`.
`Cam OII
`
` .u Evanrator
`
`w‘aIurEvn mated
`
`1 Centrifuge
`
`\
`
`4
`
`ihslhr
`
`[hslhr
`
` 1
`
`WuIGral:1a 0 Syrup
`SEIVHS
`31 355
`on
`2 1%
`Water
`is1-1.
`
`**'§!%"
`
`Qgggnuccusfs
`Fun! Rnqlllmzl EyDrynv(De=nLII-.rm))
`0nrIm|Im can put ha|.ralS5IDecaIhnlm
`KWH naqulmd ?.7y|]nunInr I A II um: cmmman
`Drmru|Ing can our In-n:rn15 rs-Kwu
`Fun Rnrwwmn By Evapnrnwrnnwuunmnsy
`Dumnllng can par Iluur anS5IDnmIhnlm
`1*_nL_a: Upnmflna Cnsl win)
`
`was
`sun
`am
`
`Mm
`549927
`$15.15
`may
`saunas
`
`may
`amen
`lEl:1'.I
`
`Prcfluctvaluu
`ulna [Cu;uI:|lyJ
`wmna m finilnn
`Earn an [Cnpnnim
`V::I|I\xJ |1IS!lJ|)Ilnn
`
`TalnIVaInIn (inn;
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication
`
`M
`
`
`
`y 15, 2008 Sheet 8 of 1]
`
`US 2008/0110577 A1
`
`RAW MATERIAL
`DLI
`2.AT-
`Snllds
`Vii?‘-
`Walar
`
`aura
`
`Ihslhr
`200,000
`4.30:)
`32,620
`152530
`
`50 mmgy Ethanol Plant
`
`
`
`I
`2 Phase Dacanlar
`“M/—
`I______, Encnnlur n Lug-nu
`
`Wash Walur
`
`Ipsmr
`3,346
`
`Ihslhr
`1aa;35a
`V.
`n-auraurunul-1
`
`
`v 959
`
`Ibslhr
`54 389
`
`73,970
`3
`..........'
`ni5u|[ur5 wag gain;
`Oi}
`-
`5.1%
`— -9 wash Watar Return
`Sulids
`arm.
`
`I‘
`Water
`mm
`Ibalhr
`I
`,
`I...
`135.611
`I
`We! Grains 4- Wash Water
`251-
`3,345
`|
`nil
`:92
`um
`on
`
`9,455
`‘7.11’-
`21,160
`|
`749-
`Snllds
`
`
`
`112 336
`um‘.
`109105
`;
`914%
`walar
`
`IIl
`
`
`
`
`
`
`
`OI!
`‘8 Q
`UiUE!I'II.IIi'E_
`
`
`Walter
`
`3.2-'.
`
`J 2‘
`x, ., I
`
`: “J
`
`V
`
`Ibsfhr
`
`
`
`lbslhr
`cancanmtnu Sllllann
`41.399
`ZBEG
`
`
`
`
`WatGrain: + Syrup
`nu
`ma
`
`Sullda
`:l2.|l5€
`aim
`L
`“t”
`lv
`
`Waiar
`
`Drver
`
`lbsfhr
`
`‘
`
`F "
`lg.
`
`8
`
`Cum Oll
`
`Ihsflur
`2.554
`
`
`
`udu
`am:
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`
`:7-rmrl
`H93
`:1DE5 |\:un::Iw;
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`
`
`31.12.24
`\n'.IIlmlnt57flfl1u|
`.$4B§21
`fluumhnu Emil unr|m.I III §5lDBH'~N!1l'F|
`
`
`
`En:-no.1 (capmyl
`521.2
`fI'\'.'H nzuuiui any U|'I=nlI1u I 5 ll um: r:mm~rur_n
`1122.53
`
`Valuud It Slflflflnfl
`l.'ll.24
`O;InrI|ln|: cm uarmu nl smmwu
`5&5
`Fm! finquilwl Hy Ew:[IIr1|\nr{lJu|:lktIunlI:)
`man
`Dzmlrq out I urlwu ul ihnnanuuarru
`
`sums:
`Tllll Vlllll fllhl}
`
`531I.14
`Inul Dpurlhnn Izustgum
`
`
`
`
`
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`
`Patent Application Publication M y 15, 2008 Sheet 9 of ll
`
`US 2008/0110577 Al
`
`RAW MATERIAL
`Ull
`Sullds
`Wa'2r
`
`in-5
`1fl.3'.i
`H.354.
`
`lhslhr
`
`,
`
`
`
`50 mmgy Ethanol Plant
`
`i
`
`_
`
`3 Fl1as.n Decanlar
`_
`
`Dll Rnbnuufl
`oil
`wam
`
`91%
`3%
`
`lbsfhr
`1,493 —:-—4 |ndn|1andnLCllPwI11I::l.hn
`1.454
`44
`
`_
`
`
`
`Wash Wafer
`‘Law on comm?
`...... ...................
`
`_
`E - -> Wash Water Return
`3
`
`
`
`'I
`
`I
`
`Dislkllers Wat Grains
`oil
`5 MI
`51.1.‘/.
`arms
`
`Ibslhr
`
`at Grains + Wash Water
`Oil
`2.5%
`Sullds
`WM
`
`lbslhr
`135,51 1
`3.345
`23.150
`
`Dacanlarluquld
`
`lhalhs
`13fi,ll(i1
`\ lb:-:F|1r
`rs-=-n-ruz-Ia
`62,891
`
`77,471
`
`
`Ibslilr
`Thin Stlllaga
`140.3527
`1,505.5
`9.459
`129.395
`
`1 1-/.
`firm
`nun
`
`~.. Evaoratar
`Valar Euanralad
`
`Ibsvh:
`103 E1!
`
`lhsihr
`36,551
`bancanlramxd Sflllage
`1505.5
`Oil
`4.1%
`
`Solids
`25.995
`5,-1&0
`
`Waler
`mu-.«.
`25 535
`
`
`
`
`
`
`
`I
`1
`I
`I
`'
`I
`l
`
`V
`
`I
`
`
`
`I E2514
` lr
`lhsfhr
`aEhecl"WatGra!n5"
`
`
` all 129:. 1.1140
`
`Sullds
`sum
`Water
`5135'-
`
`
`’, Centrifuge
`vim...
`é“'fl
`
`lhslhr
`
`Wat Grains 1- Syrup2.1-.£
`:s.a~.s
`
`2.853
`
`Fig. 9
`
`Gnfll OII
`
`Ll:sJJ1I'
`
`an
`EE|'l"J
`EB‘-1
`
`Sm:
`
`Su|T|1.TA
`s:n.u4
`$79114
`mu:
`
`1=rudu:IwI3,..
`DUES lciwnaltyl
`Vnmon at srnnnn
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`\/aluudnl5300/lm
`Tuln|Vn|m($|\1r]
`
`Eng
`2.1572»
`:|:n.n
`
`gm
`
`51:15.05
`§_|2_1,._E§
`t1.uq,un
`
`\
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`J
`1
`
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`DPE
`
`Fmifinuurnd Er D:':V1r{Dm:alhann:|
`Dnnrnllng Dual pnr hour at Sfimuznll arm
`K\VHm:uI|m:vyDum1tnr\fl-Ilnnd :.m.rir.r;u
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`Dpttlflug Baal pm m:urnl5i'Dn=mcI=rI
`
`
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`
`Patent Application Publication M y 15, 2008 Sheet 10 of 11
`
`US 2008/0110577 A1
`
`RAW MATERIAL
`DII
`14*.‘
`15.1%
`51.3%
`
`walar
`
`5|) mmgy Ethanol Plant Sullfis
`162.EBD
`
`lbs/nr
`2U0.0E|€|
`4.UUU
`sumo
`
`5 g
`
`3 Phase Decanter
`1
`_ .
`F I
`I (O
`
`Sullds
`
`
`5.1%
`57.5%57.0%
`
`I‘.IlI Dlichnmu
`an
`Walur
`Dnn:mte:ILluId
`Wash ‘Namr
`“Law OII cannmc"
`7; 97“;
`n nu u mu .. .... . mu.
`
`lhsfhr
`‘I .527
`1.454
`T3
`Ibsfhr
`136 E31
`
`55%
`5%
`
`A‘ lhslhr
`
`Dunn!-r|Jn\-Ill
`
`32,862]
`
`
`
`
`
`- + Washwatarmlum
`
`T7335}
`
`140.1 47
`Thin Stillaga
`Oil
`1-4%
`1 520.0
`
`
`Sands
`2.79.
`9,480
`95.9%
`1 El! 767
`
`
`
`
`1‘
`Wat Grains + Wash Wnlar
`2.5%
`Oil
`
`Ins».
`Sulids
`
`Wale:
`non.
`
`Ihslhr
`135,511
`3.345
`
`23.150
`1139.105
`
`
`
`l
`
`3 Phase Denantar
`_..-___.__..i
`nil D schmga (wt passmlu In-npunuas.
`
`
`
`1 CH] Furlflaalinn
`he wmar!
`r‘ H3
`-n Evagzoralnr
`Weller Eva
`ralad
`
`lbslhr
`H12 214
`
`A5 Rnquand
`
`
`
`‘. Q
`
`55 195
`
`Wal Grains + Syrup
`Oil
`LLB:
`Solids
`319‘?-
`Wa1er
`51.1%
`
`D El’
` ’ Wala: Eva nzalnd
`[
`lbslhr
`37,543
`1.920
`32,520
`3 DUB
`
`5.1%
`11—E'£
`‘ID |‘l'/E
`
`Corn OI1
`
`Ihslhr
`2830
`
`mm
`Ernducl Vgyn
`
`
`a75a:..r.
`nuns (cups.-.11)
`FIn:\i1M;|‘rud By Dn'nr qu-uuumup
`
`opnmnng Dual pm-um alS5lDn:nfluIIfl‘I
`54711122
`\lnlMnh1‘57‘£IflhII
`si.1I4.m
`
`
`
`
`-KWH ruqulrul IN Dncnmnr I a. n ma cunmlugn
`554.:
`cum ui £Eupau|y|
`zamn
`
` Wm: at Iaunnm mm
`flnumflm Em! var rm -|5.n5mvm
`551 :1
`
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`E15
`
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`5151.1
`Tnutl Unlrflbu Cull [Slim
`T|IlniViDI fl.'h|'|
`31.71531
`
`
`
`gm
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`Patent Application Publication M
`
`
`
`y 15, 2008 Sheet 1] of 1]
`
`US 2008/0110577 A1
`
`RAW MATERIAL
`Z4“
`
`50 mmgy Ethanol Plant llini
`152,5BD
`
`Ihslhr
`zIJu,nou
`4 ‘EDD
`32,620
`
`1
`
`2 Phase Dacanlar
`
`r-’’ '
`('0
`
`Q
`m5|i"3,-5 wag Q;-ding
`on
`saw.
`Water
`57.115;
`Sullds
`37.6%
`1.
`lllslhr
`Wnl Gralns +Wash water
`1:55.611
`
`3345
`2.5»:
`cm
`23.15::
`sand;
`mes
`.
`Wa1ar
`nus-.a
`109,121:
`1
`3 Phase Dacalller
`
`Ihsfhr
`3.
`n-=-M-ILI1--I-i
`
`lbalhr
`6-£339]
`
`76:13?
`
`140.525
`1.454
`5,450
`129 E12
`
`
`
`I- -> Wash WMH Return
`I
`.
`I
`1
`1
`.
`I
`:1
`
`oil
`Enllds
`wmer
`
`cm.
`an
`In-2%
`
`
`
`
`I__._.
`
`73370
`Wash Watnr
`:..........................uu
`
`lhslhr
`3,345
`35 ‘I35
`23,160
`
`
`
`D1! Purmcallun
`A! R:
`Irlmd
`H
`
`E at £[a;n[
`Wauar Evagnralnn
`
`Ibslhr
`134,195
`
`
`
`
`
`Ilzslhr
`Eunnnnlrntnd Etlllngn
`35,331
`Clll
`NM
`1454
`
`sullds
`E W-
`9.430
`Wallzr
`7U.uv.
`25466
`
`
`
`lcentrlfuga
`
`
`Ibsfhl‘
`
`Wal Gvains -6 Synlp
`ml
`1.1%
`Sullds
`:4.n’.
`
`W“
`
`Fig. 11
`
`(_§Em Oil
`
`lhufllr
`2.536
`
`int
`Egznfucl yahln
`
`nuns Ibupndlyl
`:7591,0
`
`Vnlu:du157llI|n-u
`51.31515
`2fl'.‘rl'|.'.|
`cam DI (Canaan)
`V|1ul.-d .1 sauunm
`£115.45
`
`$1,141.13
`
`
`
`
`
`
`Elpor:|I!ngI:nr.||\Irhu1n| ssmncamann
`
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`EH21
`saum
`nun.-..L..n am; [in my .1 us/Kwn
`5!-8
`Fual Hrmllul BI Evl.-oral-I [Dnumu-vr.s)
`
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`
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`
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`
`
`
`
`
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`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`US 2008/01 10577 A1
`
`May 15, 2008
`
`IVIETIIOD AND SYSTEMS FOR ENHANCING
`OIL RECOVERY FROM ETHANOL
`PRODUCTION BYPRODUCTS
`
`[0001] This application is a continuation of PCT Applica-
`tion PCT./US2006/09238, which claims the benefit of U.S.
`Provisional Patent Application Ser. No. 60/661,733, filed
`Mar. 15, 2005, the disclosures of which are incorporated
`herein by reference.
`
`COPYRIGHT STATEMENT
`
`[0002] A portion of the disclosure of this document con-
`tains material subject to copyright protection. No objection is
`made to the facsimile reproduction o ‘the patent document or
`this disclosure as it appears in the Patent and Trademark
`Office files or records, but any and a 1 rights in the copyright
`(s) are otherwise reserved.
`TECHNICAL FIELD
`
`[0003] The present invention relates generally to producing
`oil from corn and, more particularly, to recovering oil from a
`byproduct of the dry milling process used to obtain ethanol
`from corn.
`
`BACKGROUND OF THE INVENTION
`
`[0004] Over the past thirty years, significant attention has
`been given to the production of ethyl alcohol, or “ethanol,” for
`use as an alternative fuel. Ethanol not only bums cleaner than
`fossil firels, but also can be produced using com, a renewable
`resource. At present, an estimated sixty—nine “dry milling”
`plants in the United States produce over three billion gallons
`of ethanol per year. Additional plants presently under con-
`struction are expected to add billions ofgallons to this total in
`an effort to meet the current high demand.
`[0005] As noted in the foregoing discussion, a popular
`method of producing ethanol from corn is known as “dry
`milling.” As is Well known in the industry, the dry milling
`process utilizes the starch in the corn to produce the ethanol
`through fermentation, and creates a waste stream or byprod-
`uct termed “whole stillage” (which may be further separated
`into byproducts commonly referred to as “distillers Wet
`grains” and “thin stillage”). Despite containing valuable oil,
`these byproducts have for the most part been treated as waste
`and used primarily to supplement animal feed. "his feed is
`mostly distributed in the form of distillers dried grains with
`solubles, which is created by evaporating the thin stillage,
`recombining the resulting concentrate or syrup with the dis-
`tillers wet grains, and drying the product to a mois ure content
`of less than about 10% by weight.
`[0006]
`Significant attention has recently been given to the
`use of oil, including corn oil, as an altemative fuel. This fuel
`oil, frequently termed “biodiesel”, is a cleaner fue than petro-
`leum—based diesel (less emissions), environmentally safe
`(spills biodegrade quickly), and can be mixed at any concen-
`tration to diesel without engine modification. "he current
`value of corn oil as biodiesel is approximately $2.40 per
`gallon, or $648/ton, which is essentially double the value of
`the commercial feed that would normally include this oil.
`Although the market for the biodiesel is growing rapidly and
`the potential profit is significant, key lin1iti11g factors are the
`cost of obtaining the oil using current techniques and the
`resulting quality.
`
`In this regard, efforts to recover usable oil fiom the
`[0007]
`byproducts of the dry milling process used to create ethanol
`have not been terribly successful in terms of efficiency. One
`proposed approach involves attempting to separate the oil
`from the thin stillage before the evaporation stage, such as
`using a centrifuge. However, spinning the thin stillage at this
`stage using a centrifiige creates an emulsion phase that typi-
`cally requires further processing before useable oil can be
`recovered. Moreover, the volume of thin stillage is generally
`2 to 10 times greater than the syrup, which is a considerable
`capital requirement to purchase the number of centrifuges
`required. Known techniques also lack the capability to maxi-
`mize the oil recovery, which leads to decreased efficiency and
`concomitant lower profits. Together. these obstacles make
`past and current attempts to recover oil from ethanol produc-
`tion byproducts, such as com thin stillage, somewhat inefii-
`cient and uneconomical.
`[0008] U.S. Pat. No. 5,250,182 (the disclosure ofwhich is
`incorporated herein by reference) describes the use of filters
`for removing substantially all solids and recovering lactic
`acid and glycerol from the thin stillage without the need for
`evaporation. Despite eliminating a step in the conventional
`process, the proposal results in a more complicated arrange-
`ment requiring multiple filtration steps. Wholesale elimina-
`tion ofthe evaporator in the vast majority of existing plants is
`also unlikely and otherwise uneconomical. Filters, and espe-
`cially the microfiltration and ultrafiltration types proposed for
`use in this patent, are also susceptible to frequent plugging
`and thus deleteriously increase the operating cost. For these
`reasons, the filtration process proposed in this patent has not
`gained widespread commercial acceptance.
`[0009] Accordingly. a need exists for more efiicient and
`economical manners of recovering oil from byproducts cre-
`ated during the dry milling of corn to produce ethanol.
`SUMMARY OF THE INVENTION
`
`In accordance with one aspect of the invention. a
`[0010]
`method of processing concentrated thin stillage created dur-
`ing a dry milling process used for producing ethanol from
`corn is disclosed. The method comprises recovering oil from
`the concentrated thin stillage and further evaporating the con-
`centrated thin stillage. Tl1e recovered oil may be used, for
`example, as biodiesel, and the leftover concentrated thin stil-
`lage dried and used as feed.
`[0011]
`In one embodiment, the recovering step co111prises
`separating the oil from the concentrate using a disk stack
`centrifuge. The disk stack centrifuge produces suspended
`solids, which may be mixed with distillers wet grains. The
`disk stack centrifirge also produces a syrup, and the method
`may further comprise mixing the syrup, the suspended solids
`and distillers Wet grains to form a mixture. Tl1e method may
`further include the step of drying the mixture.
`[0012]
`In accordance with another aspect of the invention,
`a method of processing thin stillage created by a dry milling
`process used for producing ethanol from corn to recover oil is
`disclosed. The method comprises evaporating the thin stillage
`to form a concentrate. At some point in time during the
`evaporating step, but before it is completed, the method also
`includes the step ofintroducing the concentrate to a disk stack
`centrifuge. The disk stage centrifuge then recovers oil from
`the concentrate.
`[0013] The method may further include the step of evapo-
`rating the concentrate after the step of using the disk stage
`centrifuge to recover oil. Preferably,
`the evaporating step
`
`(cid:0)+(cid:0)<(cid:0)’(cid:0)5(cid:0),(cid:0)7(cid:0)((cid:0)(cid:3)(cid:0)((cid:0);(cid:0)+(cid:0),(cid:0)%(cid:0),(cid:0)7(cid:0)(cid:3)(cid:0)(cid:20)(cid:0)(cid:19)(cid:0)(cid:20)(cid:0)(cid:21)
`

`
`US 2008/Ol 10577 A]
`
`May 15, 2008
`
`comprises using a multi—stage evaporator to form the concen-
`trate from the thin stillage and the step of introducing the
`concentrate to a disk stack centrifuge is completed before the
`last stage of the evaporator. The evaporator most preferably
`includes at least one scraped surface heat exchanger.
`[0014]
`In accordance with still another aspect of the inven-
`tion, a method of recovering oil from thin stillage created by
`a dry milling process used for producing ethanol from com is
`disclosed. The method comprises using a multi—stage evapo-
`rator to fonn a concentrate from the thin stillage. Before the
`last stage of the evaporator, the method includes recovering
`oil from the concentrate.
`[0015]
`In one embodiment, the method of this aspect of the
`invention further includes the step of fiirther evaporating the
`concentrate remaining after the recovering step.
`[0016]
`In accordance with a further aspect of the invention,
`a method of processing whole stillage resulting from the dry
`milling of corn to form ethanol is disclosed. The method
`comprises recovering thin stillage including solids from the
`whole stillage; concentrating the thin stillage including the
`solids; and recovering oil from the thin stillage before the
`concentrating step is complete.
`[0017]
`In accordance with yet another aspect of the inven-
`tion, a subsystem for intended use in a system for producing
`ethanol by dry milling com and creating thin stillage as a
`byproduct is disclosed. The system comprises a multi—stage
`evaporator for evaporating the thin stillage, as well as means
`for receiving thin stillage before the last stage of the evapo-
`rator and recovering oil therefrom.
`[0018]
`In one embodiment,
`the n1ulti-stage evaporator
`includes two distinct evapo rators. These evaporators are sepa-
`rated by a disk stack centrifiige serving as the receiving and
`recovering means. Mo st preferably. the evaporator includes at
`lea st one scraped surface heat exchanger.
`[0019]
`In accordance with another aspect of the invention,
`a method of processing a byproduct of a dry milling process
`used for producing ethanol from corn is disclosed. The
`method comprises washing the byproduct to create wash
`water including oil, concentrating the wash water; and recov-
`ering oil froin the concentrated wash water.
`[0020]
`In one embodiment, the byproduct is whole stillage
`and the washing step comprises delivering the whole stillage
`to a first decanter for producing thin stillage and distillers wet
`grains. In such case, the method may further include the step
`of washing the distillers wet grains. In particular, the step of
`washing the distillers wet grains may comprise delivering the
`distillers wet grains to a second decanter for producing
`washed wet grains and the wash water used in the concentrat-
`ing step. The thin stillage may be combined with the wash
`water before the concentrating step.
`[0021]
`In accordance with still a further aspect oftlie inven-
`tion, a system for processing whole stillage produced from
`dry milling corn is disclosed. The system comprises a first
`separator for receiving the whole stillage and creating at least
`thin stillage and distillers wet grains. A second separator
`receives the distillers wet grains zmd wash water for creating
`washed wet grains and an oil—bearing discharge (e.g., wash
`water or an oil phase). Means for recovering oil from the
`oil—bearing discharge is also provided.
`[0022]
`In one embodiment, the first separator is a two phase
`decanter for producing wash water delivered to the second
`separator. Preferably, the second separator is a two phase
`decanter, but may instead be a three phase decanter. An evapo -
`rator may be provided for receiving the thin stillage and wa sh
`
`water to form a concentrate, along with a third separator for
`recovering oil from the concentrate. The system may further
`include a dryer for drying a combination of the washed wet
`grains and any concentrate remaining after recovering oil
`using the third separator. The evaporator may be a multi—stage
`evaporator and the third separator comprises a disk-stack
`centrifuge that receives the concentrate before the last stage
`of the evaporator.
`[0023]
`In accordance witl1 still another aspect of the inven-
`tion, a system for processing thin stillage and distillers wet
`grains produced from dry milling corn is disclosed. The sys-
`tem comprises a first separator for receiving the distillers wet
`grains and creating at least washed wet grains and wash water.
`A11 evaporator evaporates the thin stillage and wash water to
`form a concentrate. A second separator recovers oil from the
`concentrate.
`[0024]
`Preferably, the first separator is a second decanter
`downstream of a first decanter for fon11ing the distillers wet
`grains and thin stillage. Either the first or second decanter
`may be a two phase decanter, or a three phase decanter. The
`second separator prefera ly comprises a disk—stack centri-
`fuge.
`In accordance with yet a further aspect ofthe inven-
`[0 025]
`tion, a system for processing whole stillage produced from
`dry milling corn is disclosed. The system comprises means
`for receiving the whole stillage and creating at least thin
`stillage, means for concentrating the thin stillage, and means
`for recovering oil from the concentrated thin stillage.
`[0026]
`In one embodiment, the means for receiving the
`whole stillage is a two phase decanter. In another, the means
`for receiving the whole stillage is a three phase decanter. hi
`still another,
`the means for receiving the whole stillage
`includes a two phase decanter followed by a three phase
`decanter, or vice versa.Yet another option is for the means for
`receiving the whole stillage to include a three phase decanter
`followed by a three phase decanter. Preferably, the means for
`concentrating is a multi—stage evaporator, and the recovering
`means is a disk-stack centrifuge. However. the means or
`device for recovering may comprise any suitable device for
`separating oil from a mixture, such as a gravity separator, a
`centrifuge, a centrifugal decanter, or an evaporator. Means for
`recovering oil using known techniques of chemical addition
`(pH adjustment, enzymatic action, etc.) may also be effective.
`[0 027]
`In accordance with one more aspect oftlie invention,
`a method forprocessingwhole stillage including oil produced
`from dry milling corn includes the steps of: