Hybrid separation

1. A separation method performed in a production facility to improve yield, the method comprising:

filtering a first large-particles stream from a first liquid stream containing small particles of a process stream by using a first mechanical separation device in a counter-flow wash process in a series;

adding water to the first large-particles stream in a tank to create a lower-solids stream;

heating the lower-solids stream in the tank; and

removing extra water from the lower-solids stream by using a second mechanical separation device in the counter-flow wash process that further separates a second large-particles stream from a second liquid stream containing small particles of the lower-solids stream;

wherein the separation method is performed downstream of liquefaction and upstream of fermentation.

2. The method of claim 1 , wherein the lower-solids stream in the tank is heated to a temperature lower than about 90° C. (about 363 K) to remove starch.

3. The method of claim 1 , wherein the lower-solids stream in the tank is heated to a temperature higher than about 100° C. (about 373 K) to leach oil.

4. The method of claim 1 , wherein the first or the second mechanical separation device comprises at least one of a multi-zoned screening apparatus, a paddle screen, a filtration centrifuge, or a pressure screen.

5. The method of claim 1 , further comprising:

sending a portion of the first large-particles stream to a shearing device;

shearing particles in the portion of the first large-particles stream by using the shearing device; and

sending the particles sheared to be combined with the water and the first large-particles stream in the tank to create the lower-solids stream.

6. The method of claim 5 , wherein the shearing the particles comprises using at least one of a disc mill, an impact mill, a roller mill, a centrifugal pump, a ventri jet, or a hydroheater.

7. The method of claim 1 , wherein the first mechanical separation device produces a solids content of about 18%.

8. The method of claim 1 , further comprising causing an increase in ethanol yield ranging from about 1% to about 3%, by fermenting the second liquid stream containing small particles to produce ethanol.

9. The method of claim 1 , further comprising recovering an increased amount of oil ranging from about 10% to about 50%, by sending the second liquid stream containing small particles through an oil recovery process to recover oil.

10. The method of claim 1 , further comprising:

adding water to the second large-particles stream in another tank to create another lower-solids stream; and

heating the another lower-solids stream in the another tank.

11. The method of claim 10 , further comprising:

filtering a third large-particles stream from a third liquid stream containing small particles of the process stream by using a third mechanical separation device; and

receiving the third large-particles stream to further separate insolubles from liquids in the third large-particles stream by using a dewatering device.