Hybrid separation
This disclosure describes techniques for using a single feedstock of barley to produce a fermented product and a method for filtering a large-particles stream from a liquid stream containing small particles of a process stream using a series of mechanical separation devices to increase yield.
1. A feedstock separation method in a production facility, the method comprising:
receiving a feedstock mixed with water to form a slurry in a tank;
filtering the slurry as a process stream to create a large-particles stream and a liquids stream containing small particles by using a multi-zoned screening apparatus, the multi-zoned screening apparatus having a first zone and a second zone situated directly adjacent to one another, and separate outlets for each of the large-particles stream and the liquids stream containing small particles;
moving the process stream in the multi-zoned screening apparatus through the first zone and the adjacent second zone via a conveyor that rotates relative to an immovable screen to direct the process stream toward the immovable screen to filter the liquids stream containing small particles from the large-particles stream, the first zone receiving the process stream and providing separation of the liquids stream containing small particles from the large-particles stream using counter-flow washing, and the second zone washing the large-particles stream with water;
sending the liquids stream containing small particles from the multi-zoned screening apparatus to a water makeup process;
sending the large-particles stream via the conveyor from the multi-zoned screening apparatus to be gravity fed to a roller mill;
shearing and compressing large particles present in the large-particles stream with rollers in the roller mill to provide a sheared and compressed large-particles stream;
mixing the sheared and compressed large-particles stream in another tank with a liquid to create a mixture; and
sending the mixture through a rotary press to separate remaining insolubles from another liquids stream.
2. The method of claim 1 , wherein the slurry comprises about 15% to about 44% solids.
3. The method of claim 1 , wherein the feedstock comprises at least one of corn, milo, barley, or sorghum grain.
4. The method of claim 1 , further comprising sending the another liquids stream to be mixed in at least one of a slurry tank, a liquefaction tank, or a water makeup process.
5. The method of claim 1 , further comprising at least one of:
sending the insolubles to be mixed with wet cake to produce wet animal feed;
sending the insolubles to be partial-dried to produce partial-dried animal feed; or
sending the insolubles to be dried to produce full-dried animal feed.
6. The method of claim 1 , wherein the insolubles comprise at least one or more of fiber, nonfermentables, germ, and grit.
7. A process stream separation method in a production facility, the method comprising:
filtering a process stream to create a large-particles stream and a liquids stream containing small particles by using a multi-zoned screening apparatus, the multi-zoned screening apparatus having a first zone and a second zone situated directly adjacent to one another, and separate outlets for each of the large-particles stream and the liquids stream containing small particles;
moving the process stream in the multi-zoned screening apparatus through the first zone and the adjacent second zone via a conveyor that rotates relative to an immovable screen to direct the process stream toward the immovable screen to filter the liquids stream containing small particles from the large-particles stream, the first zone receiving the process stream and providing separation of the liquids stream containing small particles from the large-particles stream using counter-flow washing, and the second zone washing the large-particles stream with water to separate starch or gluten from the large-particles stream;
sending a portion of the large-particles stream from the second zone of the multi-zoned screening apparatus to a roller mill;
shearing and compressing the large-particles stream through rollers in the roller mill;
mixing the sheared and compressed large-particles stream in a tank with a liquid to create a mixture; and
sending the mixture through a rotary press to separate remaining insolubles from another liquids stream.
8. The method of claim 7 , further comprising sending the another liquids stream to be mixed in at least one of a slurry tank, a liquefaction tank, or a water makeup process.
9. The method of claim 7 , wherein the rotary press removes moisture from the mixture, the mixture having up to 64% moisture content after being sent through the rotary press.
10. The method of claim 7 , wherein the multi-zoned screening apparatus comprises at least one of a paddle screen, a filtration centrifuge, or a pressure screen.