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Title: The production of fuels and chemicals from food processing wastes using a novel fermenter separator. Annual progress report, January 1991--December 1991

Abstract

During 1991, considerable progress was made on the waste utilization project. Two small Wisconsin companies have expressed an interest in promoting and developing the ICRS technology. Pilot plant sites at (1) Hopkinton, IA, for a sweet whey plant, and Beaver Dam WI, for an acid whey site have been under development siting ICRS operations. The Hopkinton, IA site is owned and operated by Permeate Refining Inc., who have built a batch ethanol plant across the street from Swiss Valley Farms cheddar cheese operations. Permeate from Swiss Valley is piped across to PRI. PRI has signed a contract to site a 300--500,000 gallon/yr to ICRS pilot plant. They feel that the lower labor, lower energy, continuous process offered by the ICRS will substantially improve their profitability. Catalytics, Inc, is involved with converting whey from a Kraft cream cheese operation to ethanol and yeast. A complete project including whey concentration, sterilization, and yeast growth has been designed for this site. Process design improvements with the ICRS focussed on ethanol recovery techniques during this year`s project. A solvent absorption/extractive distillation (SAED) process has been developed which offers the capability of obtaining an anhydrous ethanol product from vapors off 3 to 9% ethanol solutionsmore » using very little energy for distillation. Work on products from waste streams was also performed. a. Diacetyl as a high value flavor compound was very successfully produced in a Stirred Tank Reactor w/Separation. b. Yeast production from secondary carbohydrates in the whey, lactic acid, and glycerol was studied. c. Lactic acid production from cellulose and lactose studies continued. d. Production of anti-fungal reagents by immobilized plant cells; Gossypol has antifungal properties and is produced by G. arboretum.« less

Authors:
; ; ; ; ; ;
Publication Date:
Research Org.:
Purdue Univ., Lafayette, IN (United States)
Sponsoring Org.:
USDOE, Washington, DC (United States)
OSTI Identifier:
10156274
Report Number(s):
DOE/CE/40772-T1
ON: DE92016653
DOE Contract Number:
FG02-85CE40772
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: Dec 1991
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 37 INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL CHEMISTRY; WHEY; WASTE PRODUCT UTILIZATION; ETHANOL; PRODUCTION; LACTIC ACID; PROGRESS REPORT; FERMENTATION; DISTILLATION; ENERGY CONSERVATION; EFFICIENCY; CHEMICAL REACTORS; 320305; 400201; INDUSTRIAL WASTE MANAGEMENT; CHEMICAL AND PHYSICOCHEMICAL PROPERTIES

Citation Formats

Dale, M.C., Venkatesh, K.V., Choi, Hojoon, Moelhman, M., Saliceti, L., Okos, M.R., and Wankat, P.C. The production of fuels and chemicals from food processing wastes using a novel fermenter separator. Annual progress report, January 1991--December 1991. United States: N. p., 1991. Web. doi:10.2172/10156274.
Dale, M.C., Venkatesh, K.V., Choi, Hojoon, Moelhman, M., Saliceti, L., Okos, M.R., & Wankat, P.C. The production of fuels and chemicals from food processing wastes using a novel fermenter separator. Annual progress report, January 1991--December 1991. United States. doi:10.2172/10156274.
Dale, M.C., Venkatesh, K.V., Choi, Hojoon, Moelhman, M., Saliceti, L., Okos, M.R., and Wankat, P.C. Sun . "The production of fuels and chemicals from food processing wastes using a novel fermenter separator. Annual progress report, January 1991--December 1991". United States. doi:10.2172/10156274. https://www.osti.gov/servlets/purl/10156274.
@article{osti_10156274,
title = {The production of fuels and chemicals from food processing wastes using a novel fermenter separator. Annual progress report, January 1991--December 1991},
author = {Dale, M.C. and Venkatesh, K.V. and Choi, Hojoon and Moelhman, M. and Saliceti, L. and Okos, M.R. and Wankat, P.C.},
abstractNote = {During 1991, considerable progress was made on the waste utilization project. Two small Wisconsin companies have expressed an interest in promoting and developing the ICRS technology. Pilot plant sites at (1) Hopkinton, IA, for a sweet whey plant, and Beaver Dam WI, for an acid whey site have been under development siting ICRS operations. The Hopkinton, IA site is owned and operated by Permeate Refining Inc., who have built a batch ethanol plant across the street from Swiss Valley Farms cheddar cheese operations. Permeate from Swiss Valley is piped across to PRI. PRI has signed a contract to site a 300--500,000 gallon/yr to ICRS pilot plant. They feel that the lower labor, lower energy, continuous process offered by the ICRS will substantially improve their profitability. Catalytics, Inc, is involved with converting whey from a Kraft cream cheese operation to ethanol and yeast. A complete project including whey concentration, sterilization, and yeast growth has been designed for this site. Process design improvements with the ICRS focussed on ethanol recovery techniques during this year`s project. A solvent absorption/extractive distillation (SAED) process has been developed which offers the capability of obtaining an anhydrous ethanol product from vapors off 3 to 9% ethanol solutions using very little energy for distillation. Work on products from waste streams was also performed. a. Diacetyl as a high value flavor compound was very successfully produced in a Stirred Tank Reactor w/Separation. b. Yeast production from secondary carbohydrates in the whey, lactic acid, and glycerol was studied. c. Lactic acid production from cellulose and lactose studies continued. d. Production of anti-fungal reagents by immobilized plant cells; Gossypol has antifungal properties and is produced by G. arboretum.},
doi = {10.2172/10156274},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Sun Dec 01 00:00:00 EST 1991},
month = {Sun Dec 01 00:00:00 EST 1991}
}

Technical Report:

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  • The basic objective of this project is to convert waste streams from the food processing industry to usable fuels and chemicals using novel bioreactors. These bioreactors should allow economical utilization of waste (whey, waste sugars, waste starch, bottling wastes, candy wastes, molasses, and cellulosic wastes) by the production of ethanol, acetone/butanol, organic acids (acetic, lactic, and gluconic), yeast diacetyl flavor, and antifungal compounds. Continuous processes incorporating various processing improvements such as simultaneous product separation and immobilized cells are being developed to allow commercial scale utilization of waste stream. The production of ethanol by a continuous reactor-separator is the process closestmore » to commercialization with a 7,500 liter pilot plant presently sited at an Iowa site to convert whey lactose to ethanol. Accomplishments during 1993 include installation and start-up of a 7,500 liter ICRS for ethanol production at an industry site in Iowa; Donation and installation of a 200 liter yeast pilot Plant to the project from Kenyon Enterprises; Modeling and testing of a low energy system for recovery of ethanol from vapor is using a solvent absorption/extractive distillation system; Simultaneous saccharification/fermentation of raw corn grits and starch in a stirred reactor/separator; Testing of the ability of `koji` process to ferment raw corn grits in a `no-cook` process.« less
  • Fundamental engineering design and operational studies were performed on reactors and separators in the area of food processing waste fermentation. These studies evaluated the fermentation kinetics and nutritional requirement of immobilized cells, and examined different packing materials and energy efficient ethanol separation concentration and recovery methods, followed by the design and construction of a pilot plant reactor unit. These data will be used to develop process design models to aid in designing energy efficient and cost effective processes for conversion of food processing wastes into chemicals. 15 refs., 17 figs.
  • The objective of this project is to perform fundamental, engineering design and operational studies in the area of food processing waste fermentation. Studies addressing the fermentation kinetics and nutritional requirement of immobilized cells and examining different packing materials and energy efficient ethanol separation concentration and recovery methods are underway. These data will be used to develop process design models to aid in designing enery efficient and cost effective processes for conversion of food processing wastes into chemicals. This project focuses on using a novel immobilized cell reactor separator (ICRS) for the production of volatile chemicals from waste food sources suchmore » as whey lactose, glucose from waste starch, or any other sort of waste fermentable carbohydrate. 53 refs., 3 figs.« less
  • During 1991, considerable progress was made on the waste utilization project. Two small Wisconsin companies have expressed an interest in promoting and developing the ICRS technology. Pilot plant sites at (1) Hopkinton, IA, for a sweet whey plant, and Beaver Dam WI, for an acid whey site have been under development siting ICRS operations. The Hopkinton, IA site is owned and operated by Permeate Refining Inc., who have built a batch ethanol plant across the street from Swiss Valley Farms cheddar cheese operations. Permeate from Swiss Valley is piped across to PRI. PRI has signed a contract to site amore » 300--500,000 gallon/yr to ICRS pilot plant. They feel that the lower labor, lower energy, continuous process offered by the ICRS will substantially improve their profitability. Catalytics, Inc, is involved with converting whey from a Kraft cream cheese operation to ethanol and yeast. A complete project including whey concentration, sterilization, and yeast growth has been designed for this site. Process design improvements with the ICRS focussed on ethanol recovery techniques during this year's project. A solvent absorption/extractive distillation (SAED) process has been developed which offers the capability of obtaining an anhydrous ethanol product from vapors off 3 to 9% ethanol solutions using very little energy for distillation. Work on products from waste streams was also performed. a. Diacetyl as a high value flavor compound was very successfully produced in a Stirred Tank Reactor w/Separation. b. Yeast production from secondary carbohydrates in the whey, lactic acid, and glycerol was studied. c. Lactic acid production from cellulose and lactose studies continued. d. Production of anti-fungal reagents by immobilized plant cells; Gossypol has antifungal properties and is produced by G. arboretum.« less
  • Fermentation costs (which increase with higher product concentration) traditionally must be balanced against product recovery costs (which decrease with product concentration). A novel reactor-separator process has been developed at Purdue University to minimize product inhibition of fermentation rates. This has been shown to exhibit very high productivities - simultaneously producing and removing a inhibitory product while maintaining a high viable cell concentration in the reactor. The objective of this study is to develop an energy efficient and economical process to convert food wastes to usable chemicals. Work is divided into two major efforts (a) an applied phase which involves designmore » and building a whey to ethanol process as well as process design and optimization and (b) a basic phase which involves investigating alternative fermentation systems and fundamental research on immobilized cell reactor systems. Accomplishments are discussed. 116 refs., 80 figs., 22 tabs.« less