Method and apparatus for improving efficiency and reliability of stillage processing

1. An apparatus for dewatering a feed stream of aqueous solids residual from a fermentation and distillation process, the apparatus comprising:

a first separation device comprising a centrifuge to clarify a stream of aqueous solids into a first sub-stream and a second sub-stream:

a mixing tank in fluid connection with the first separation device to receive the first sub-stream and to provide a third sub-stream;

an evaporator in fluid communication to the first separation device to receive the second sub-stream and to provide a fourth sub-stream to the mixing tank;

a second separation device in fluid connection with the mixing tank to receive the third sub-stream and to clarify the third sub-stream into a fifth sub-stream and a sixth sub-stream, and

wherein the second separation device comprises a screw press, a centrifuge, a rotary vacuum-drum filter, or a belt filter press.

2. The apparatus of claim 1 , wherein the first sub-stream comprises less than about 32 weight percent (wt %) total solids.

3. The apparatus of claim 1 , wherein the centrifuge is a solid bowl decanter centrifuge.

4. The apparatus of claim 1 , further comprising one or more pH adjusting apparatuses in fluid communication with the mixing tank.

5. The apparatus of claim 1 , further comprising one or more boiler blowdown apparatuses in fluid communication with the mixing tank.

6. The apparatus of claim 1 , further comprising one or more dewatering aide apparatuses in fluid communication with the mixing tank and the third sub-stream.

7. The apparatus of claim 1 , further comprising a dryer in fluid communication with second separation device for drying the fifth sub-stream.

8. The apparatus of claim 7 , wherein the evaporator is in fluid communication with the dryer and provides a syrup to the fifth sub-stream.

9. An apparatus for dewatering a feed stream of aqueous solids residual from a fermentation and distillation process, the apparatus comprising:

a first separation device comprising a centrifuge to clarify a stream of aqueous solids into a first sub-stream and a second sub-stream;

a mixing tank in fluid connection with the first separation device to receive the first sub-stream and to provide a third sub-stream;

an evaporator in fluid communication to the first separation device to receive the second sub-stream and to provide a fourth sub-stream to the mixing tank;

a second separation device in fluid connection with the mixing tank to receive the third sub-stream and to clarify the third sub-stream into a fifth sub-stream and a sixth sub-stream,

wherein the second separation device comprises a hydrocyclone, a screen bend, or a clarifier;

a third separation device in fluid connection with the second separation device and to receive the sixth sub-stream and to clarify the sixth sub-stream into a seventh sub-stream and an eighth sub-stream, and

wherein the third separation device comprises a screw press, a centrifuge, or a belt filter press.

10. The apparatus of claim 9 , wherein the first sub-stream comprises less than about 32 weight percent (wt %) total solids.

11. The apparatus of claim 9 , wherein the centrifuge is a solid bowl decanter centrifuge.

12. The apparatus of claim 9 , further comprising one or more pH adjusting apparatuses in fluid communication with the mixing tank.

13. The apparatus of claim 9 , further comprising one or more boiler blowdown apparatuses in fluid communication with the mixing tank.

14. The apparatus of claim 9 , further comprising one or more dewatering aide apparatuses in fluid communication with the mixing tank and the sixth sub-stream.

15. The apparatus of claim 9 , further comprising a dryer in fluid communication with third separation device for drying the seventh sub-stream.

16. The apparatus of claim 15 , wherein the evaporator is in fluid communication with the dryer and provides a syrup to the seventh sub-stream.

17. An apparatus for dewatering a feed stream of aqueous solids residual from a fermentation and distillation process using corn or milo, the apparatus comprising:

a first separation device comprising a solid bowl decanter centrifuge to clarify a stream of aqueous solids into a first sub-stream and a second sub-stream,

wherein the first sub-stream comprises less than about 32 weight percent (wt %) total solids;

a mixing tank in fluid connection with the first separation device to receive the first sub-stream and to provide a third sub-stream;

an evaporator in fluid communication to the first separation device to receive the second sub-stream and to provide a fourth sub-stream to the mixing tank;

a second separation device comprising a hydrocyclone in fluid connection with the mixing tank to receive the third sub-stream and to clarify the third sub-stream into a fifth sub-stream and a sixth sub-stream;

a third separation device comprising a screw press in fluid connection with the second separation device and to receive the sixth sub-stream and to clarify the sixth sub-stream into a seventh sub-stream and an eighth sub-stream;

a dryer in fluid communication with third separation device for drying the seventh sub-stream,

wherein the evaporator is in fluid communication with the dryer and provides a syrup to the seventh sub-stream;

one or more pH adjusting apparatuses in fluid communication with the mixing tank;

one or more boiler blowdown apparatuses in fluid communication with the mixing tank; and

one or more dewatering aide apparatuses in fluid communication with the mixing tank and the sixth sub-stream.

18. The apparatus of claim 17 , further comprising a first transfer pump in fluid communication with the second separation device and the mixing tank.

19. The apparatus of claim 17 , further comprising a second transfer pump in fluid communication with the first separation device and a beer column.

20. The apparatus of claim 19 , wherein the second transfer pump is to deliver the stream of aqueous solids from the beer column to the first separation device.