Process for the production of animal feed and ethanol and novel animal feed

• US 20060251764A1
• Filed: 04/18/2006
• Published: 11/09/2006
• Est. Priority Date: 04/19/2005
• Status: Active Grant

• Current Assignee: Archer Daniels Midland Company
• Original Assignee: Archer Daniels Midland Company
• Inventors: Binder, Thomas P., Holzgraefe, David P., Doane, Perry H., Cecava, Michael J., Abbas, Charles, Solheim, Leif P., Beery, Kyle E.
• Granted Patent: US 7,494,675 B2
• Time in Patent Office: Days
• US Class Current: 426/53
• CPC Class Codes: A23K 10/12 by fermentation of natural products, e.g. of vegetable material, animal waste material or biomass
• CPC Class Codes: A23K 10/37 from waste material from hydrolysates of wood or straw A23K10/32; from molasses A23K10/33
• CPC Class Codes: A23K 10/38 from distillers' or brewers' waste
• CPC Class Codes: A23K 50/10 for ruminants
• CPC Class Codes: A23L 33/105 Plant extracts, their artificial duplicates or their derivatives
• CPC Class Codes: A23L 33/21 Addition of substantially indigestible substances, e.g. dietary fibres
• CPC Class Codes: A23L 7/107 Addition or treatment with enzymes not combined with fermentation with microorganisms
• CPC Class Codes: B02B 1/08 Conditioning grain with respect to temperature or water content air containing or ventilating of silos F24F; drying apparatus F26B; hygrometers G01N
• CPC Class Codes: B02B 3/00 Hulling; Husking; Decorticating decorticating textile fibres D01B1/14; Polishing; Removing the awns in threshing machines A01F12/42; Degerming
• CPC Class Codes: C12P 7/06 Ethanol, i.e. non-beverage
• CPC Class Codes: Y02E 50/10 Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02P 60/87 Re-use of by-products of food processing for fodder production

Abstract

A method for the production of ethanol and a modified animal feed is provided. The method replaces the starch in known corn-based animal feed with biomass fiber treated to make it more digestible by animals. The process includes wherein the pericarp and germ are removed from the corn kernel and processed for by-products. The starch and protein are also removed and separated. The starch is then fermented and distilled to ethanol and stillage. The bioavailable modified animal feed comprises the pericarp and germ removed from corn kernels and optionally by-products of the pericarp and germ processing, and lignocellulosic materials. The modified animal feed may optionally include energy materials such as animal and vegetable fats, vegetable soapstocks, or glycerin, and combinations thereof.

Claims

1. A method for processing corn kernels comprising the steps of:

removing the pericarp from said corn kernels;

removing the germ from said corn kernels, resulting in a starch and a protein;

separating said protein from said starch; and

liquefying and saccharifying and fermenting said starch to produce a fermented starch broth.

2. The method of claim 1 including liquefying said separated starch before said saccharification and fermentation of said starch.

3. The method of claim 1 comprising distilling said fermented starch broth to obtain a high-proof ethanol and stillage.

4. The method of claim 1 including wherein said step of removing said pericarp comprises the steps of:

chemically separating said pericarp from the remainder of said corn kernel by alkali debranning, acid debranning, or gaseous or liquid ammonia addition of said corn kernel; and

milling said separated pericarp.

5. The method of claim 1 including wherein said step of removing said pericarp comprises the steps of:

conditioning said corn kernels with steam or hot water having a temperature from about 50°

C. to about 99°

C.; and

milling said corn kernels to abrade and remove said pericarp.

6. The method of claim 1 including wherein step of removing said germ from said corn kernels comprises the steps of:

utilizing a lactic acid steeping to hydrolyze the chemical bonds between the endosperm and said germ or utilizing enzyme hydrolysis to separate said germ from the endosperm; and

milling said corn kernel to remove said germ.

7. The method of claim 1 comprising the steps of:

processing said starch and protein to remove oils and sterols therefrom; and

milling said starch to granularize said starch.

8. The method of claim 1 including wherein said step of separating said starch and protein is accomplished utilizing a method selected from a group consisting of clam shell processing, centrifuge processing, solubilization of said starch portion by enzyme saccharification, jet cooking and membrane filtration.

9. The method of claim 3 comprising the step of removing fermentation solids from said fermented starch prior to said step of distilling.

10. The method of claim 9 comprising the steps of:

pretreating a biomass fiber comprising one or more plant-derived lignocellulosic materials, agricultural processing residues, or by-products, and combinations thereof to enhance digestibility thereof for a ruminant; and

mixing said pretreated lignocellulosic materials, agricultural processing residues or by-products with said fermentation solids removed prior to the distillation of said starch.

11. The method of claim 10 including wherein said lignocellulosic materials are pretreated by mixing with stillage having a temperature of from about 80°

C. to 99°

C. obtained from the step of distillation of said fermentation broth.

12. The method of claim 1 comprising the step of processing said removed pericarp to obtain by-products.

13. The method of claim 12 including wherein said by-products of said pericarp processing include phytosterols, hemicelluloses, ferulic acid, and coumaric acid.

14. The method of the claim 1 including wherein said removed germs are processed to extract oil and nutraceuticals therefrom.

15. The method of claim 10 comprising the step of mixing said removed pericarp and said removed germ with said mixed pretreated lignocellulosic materials or agricultural processing residues or by-products and fermentation solids to produce a bioavailable modified feedstock.

16. The method of claim 12 comprising the step of processing said removed pericarp to obtain pericarp by-products.

17. The method of claim 14 comprising the step of processing said removed germ to obtain germ by-products.

18. The method of claim 17 comprising the step of mixing said pericarp by-products and said germ by-products with said mixed pretreated lignocellulosic materials and fermentation solids and energy materials comprising at least one of animal fat, vegetable fat, vegetable soapstocks, and glycerin, and combinations thereof, to produce a bioavailable modified animal feed.

19. A bioavailable modified animal feed comprising:

pericarp removed from corn kernels;

germ removed from corn kernels; and

a pretreated biomass fiber comprising lignocellulosic material, said modified animal feed comprising a starch content from about 5 to about 15 percent by weight.

20. The bioavailable modified animal feed of claim 19 comprising at least one energy material comprising one or more of an animal fat, a vegetable fat, a vegetable soapstock, and a glycerin, and combinations thereof.

21. The bioavailable modified animal feed of claim 20 comprising fermentation solids obtained as a by-product of fermenting corn starch.

22. The animal feed of claim 19 comprising:

pericarp by-products of the processing of pericarp from corn kernels; and

germ by products of the processing of germ removed from corn kernels.