Process for improving the yield and efficiency of an ethanol fermentation plant

1. A process for improving the yield and efficiency of an ethanol fermentation plant comprising:

receiving fermentable corn-based feedstock material;

destructing fatty acids present in the fermentable corn-based feedstock material prior to fermentation by adding one or more enzymes to the corn-based feedstock material, wherein the one or more enzymes are selected to destruct fatty acids present in the corn-based feedstock material and include a decarboxylase;

fermenting the feedstock with yeast to produce ethanol;

producing stillage as a by-product of ethanol fermentation;

separating the stillage into thin stillage and wet distillers grain;

directly introducing at least a portion of the wet distillers grain to an anaerobic digester to produce methane; and

recovering digestate solids from the anaerobic digester as cattle feed.

2. The process according to claim 1 , further comprising the step of adding one or more enzymes to the fermentable corn-based feedstock material prior to fermentation of the feedstock material, wherein the one or more enzymes is selected to destruct cellulose, hemicellulose, and lignin present in the feedstock, wherein the enzymes comprise a cellulase, a hemicellulase, and a ligninase.

3. The process according to claim 2 , wherein the enzymes selected to destruct cellulose, hemicellulose, and lignin are selected from beta-glucosidases, alpha-amylase, glucanase, xylanase, pectinases, β-mannosidase, proteases, ligninases, amylases, and mixtures thereof.

4. The process according to claim 1 , further comprising the steps of:

separating a liquid fraction from the thin stillage comprising the steps of:

adding a flocculant to the thin stillage, wherein the flocculant comprises an anionic polyacrylamide polymer having a molecular weight in range of about 8 to 25 million and having from about 25 to 50 mole percent anionic charge, said flocculant facilitating the formation of a solid fraction of the thin stillage;

recovering the solid fraction and the liquid fraction of the thin stillage; and

recycling the liquid fraction of the thin stillage to be combined with the fermentable feedstock.

5. The process according to claim 1 , further comprising the step of adding a surfactant to the fermentable feedstock.

6. The process according to claim 5 , wherein the surfactant comprises a linear alkyl alkoxylate.

7. The process according to claim 4 , further comprising the step of adding a surfactant to the recycled liquid fraction.

8. A process for improving the yield and efficiency of an ethanol fermentation plant comprising:

receiving fermentable corn-based feedstock material;

destructing fatty acids present in the fermentable corn-based feedstock material prior to fermentation by adding one or more enzymes to the corn-based feedstock material, wherein the one or more enzymes are selected to destruct fatty acids present in the corn-based feedstock material and include a decarboxylase;

fermenting the feedstock with yeast to produce ethanol;

producing stillage, comprising a solid fraction of the stillage and thin stillage, as a by-product of ethanol fermentation;

separating a liquid fraction from the thin stillage comprising the steps of:

adding a flocculant to the thin stillage, wherein the flocculant comprises an anionic polyacrylamide polymer having a molecular weight in range of about 8 to 25 million and having from about 25 to 50 mole percent anionic charge, said flocculant facilitating the formation of a solid fraction of the thin stillage; and

recovering the solid fraction of the thin stillage and the liquid fraction of the thin stillage;

recycling the liquid fraction of the thin stillage to be combined with the fermentable feedstock, wherein from 70-85% of the total dissolved solids (TDS) are eliminated from the liquid fraction separated from the thin stillage, and wherein the liquid fraction comprises 700 mg/L or less total suspended solids (TSS); and

directly introducing a portion of the solid fraction of the thin stillage to an anaerobic digester to produce methane.

9. A process for improving the yield and efficiency of an ethanol fermentation plant comprising:

receiving fermentable corn-based feed stock material;

adding a decarboxylase to the fermentable corn-based feedstock material prior to fermentation of the feedstock material to destruct fatty acids present in the corn-based feedstock material;

adding one or more enzymes to the fermentable corn-based feedstock material prior to fermentation of the feedstock material, wherein the one or more enzymes is selected to destruct cellulose and hemicellulose present in the feedstock;

adding a surfactant to the fermentable corn-based feedstock, wherein the surfactant comprises a linear alkyl alkoxylate;

producing stillage as a by-product of ethanol fermentation comprising a solid fraction of the stillage and thin stillage;

separating a liquid fraction from the thin stillage component of the stillage comprising the steps of:

adjusting the thin stillage pH to a value in the range from 6 to 8.5;

adding a flocculant to the thin stillage, wherein the flocculant comprises an anionic polyacrylamide polymer having a molecular weight in range of about 8 to 25 million and having from about 25 to 50 mole percent anionic charge, said flocculant facilitating the formation of a solid fraction of the thin stillage;

recovering the solid fraction and the liquid fraction of the thin stillage; and

recycling the liquid fraction of the thin stillage to be combined with the fermentable feedstock; and directly introducing at least a portion of the solid fraction of the thin stillage, with no anaerobic digestion catalyst present, to an anaerobic digester to produce methane.

10. The process according to claim 9 , wherein the one or more enzymes selected to destruct cellulose and hemicellulose present in the feedstock comprise a cellulase and a hemicellulase.

11. The process according to claim 10 , wherein the enzymes selected to destruct cellulose and hemicellulose are selected from beta-glucosidases, alpha-amylase, glucanase, xylanase, pectinases, β-mannosidase, proteases, ligninases, amylases, and mixtures thereof.

12. The process according to claim 4 , wherein the polyacrylamide polymer has a molecular weight in range of about 18 to 20 million.

13. The process according to claim 8 , wherein the polyacrylamide polymer has a molecular weight in range of about 18 to 20 million.

14. The process according to claim 9 , wherein the polyacrylamide polymer has a molecular weight in range of about 18 to 20 million.

15. The process according to claim 4 , wherein the liquid fraction separated from the thin stillage comprises 700 mg/L or less total suspended solids (TSS).

16. The process according to claim 9 , wherein the liquid fraction separated from the thin stillage comprises 700 mg/L or less total suspended solids (TSS).

17. The process according to claim 4 , wherein from 70-85% of the total dissolved solids (TDS) are eliminated from the liquid fraction separated from the thin stillage.

18. The process according to claim 9 , wherein from 70-85% of the total dissolved solids (TDS) are eliminated from the liquid fraction separated from the thin stillage.

19. The process according to claim 1 , wherein no cattle manure is present in the portion of the wet distillers grain directly introduced to the anaerobic digester.

20. The process according to claim 8 , wherein no anaerobic digestion catalyst is present in the portion of the solid fraction of the thin stillage directly introduced to the anaerobic digester.