Abstract
The present invention pertains in general to a system and method for the separation alpha-acids and other desirable compounds from post-process fermentation solids which are otherwise subject to discard after being used for a fermentation process such as the brewing of beer. The system and method, although described surrounding use with alpha-acids as associated with a beer brewing process, can be used in the extraction of soluble compounds from solids generically.
Claims
1. A system for the extraction of alpha-acids from post-process solids comprising: a mixing mechanism comprising a reservoir and a mixing element disposed therein; the reservoir having connection to a dehydrator; a distilling mechanism comprising an output having connection to a holding vessel; a drying mechanism having a drying chamber further comprising a nozzle configured to spray into the drying chamber; an air-heater configured to heat air entering the drying chamber; and the drying mechanism further comprising a first collection vessel connected to the drying chamber; wherein the mixing reservoir is configured to receive solids and a solvent for mixing in order to dissolve alpha-acids into a solution comprising solvent, water and alpha-acids; wherein the dehydrator is configured to separate the solution from the solids, wherein the distilling mechanism is configured to separate the solvent from the solution, and wherein drying mechanism is configured to separate the alpha-acids from the solvent.
2. The system of claim 1, wherein an air-pump has connection to the drying mechanism.
3. The system of claim 2, wherein the air-pump is configured to induce a negative air-flow, thereby drawing air though the air-heater and into the drying chamber.
4. The system of claim 3 wherein, the air-heater is configured to induce a cyclonic air-flow within the drying chamber.
5. The system of claim 4, wherein the nozzle comprises a spinning nozzle configured to provide 360-degree delivery of droplets.
6. The system of claim 5, further comprising a cyclonic separator connected to the drying chamber, wherein the cyclonic separator is connected downstream of the drying chamber.
7. The system of claim 6, wherein the cyclonic separator further comprises a second collection vessel.
8. The system of claim 2, further comprising a cyclonic separator connected to the drying chamber, wherein the cyclonic separator is connected downstream of the drying chamber.
9. The system of claim 8, wherein the cyclonic separator further comprises a second collection vessel.
10. The system of claim 9, further comprising a pump configured to deliver the solution to the nozzle.
11. The system of claim 10, further comprising a holding vessel wherefrom the pump draws the solution to deliver to the nozzle.
12. A method for the extraction of alpha-acids from post-process solids comprising the steps of: combining a plant-based material with a solvent to produce a slurry; dehydrating the plant-based material; mixing the slurry to dissolve alpha-acids from the plant-based material with the solvent, resulting in a solution comprising the solvent and the alpha-acids; separating the solution from the plant-based material; distilling the solution to remove the solvent from the solution; drying the solution through pressurized delivery of the solution through a nozzle into a dry environment to evaporate the water from the alpha-acids; and collecting the alpha-acids.
13. The method of claim 12, wherein a step of diluting the solution with water occurs prior to the distilling step.
14. The method of claim 12, wherein a step of settling the solution occurs prior to the drying step.
15. The method of claim 12, wherein a step of cooling the solution occurs prior to the drying step.
Description
BRIEF DESCRIPTION OF FIGURES
[0024] FIG. 1AA diagrammatic view of certain embodiments of a system for the extraction of alpha-acids from post-process fermentation solids
[0025] FIG. 1BA diagrammatic view of a dehydrator
[0026] FIG. 1CA diagrammatic view of a mixing mechanism and filtering unit
[0027] FIG. 1DA diagrammatic view of a distilling unit
[0028] FIG. 2AA diagrammatic system view of certain embodiments of a system for the extraction of alpha-acids from post-process fermentation solids
[0029] FIG. 2BA diagrammatic view of a mixing mechanism and dehydrator
[0030] FIG. 2CA diagrammatic view of a distilling unit
[0031] FIG. 2DA diagrammatic view of a drying apparatus
[0032] FIG. 3A method for the extraction of alpha acids from post-process solids
DETAILED DESCRIPTION
[0033] Certain embodiments as shown in FIG. 1A comprise a system to extract alpha-acids from post-process solids having a solvent reservoir 1010, a dehydrator 1030, a mixing mechanism 1050, a filtering unit 1060, a distilling unit 1070, and a solvent recapture reservoir 1080. In certain embodiments, shown in FIG. 1B, comprise a raw material reservoir 1100, the dehydrator 1030 and a dehydrator output 1120. The raw material reservoir 1100 feeds post-process solids to the dehydrator 1030, which is configured to separate water content from post-process solids. It will be appreciated that a dehydrator 1030 may include any dehydration apparatus known to those skilled in the art including, but not limited to a dehydrate extruder. A dehydrator output 1120 is connected to a solvent reservoir output 1090 at a mixing point 1030. The mixture of solvent and dehydrated post-process solids enters the mixing mechanism 1050 through a mixing mechanism input 1030 as shown in FIG. 1C. In some embodiments, the mixing mechanism 1050, comprises a closed loop 1140, recirculating pump 1150, and output valve 1160. The mixture of solvent and post-process solids is recirculated with the recirculating pump 1150 around the closed loop 1140 to create a slurry. The output valve 1160 is actuated to allow the mixture to exit the mixing mechanism 1050. It will be appreciated that other embodiments of a mixing mechanism 1050 may comprise other mixing mechanisms known to those skilled in the art. When the output valve 1060 is opened, the slurry passes through an output 1170 of the mixing mechanism 1050, through a filtering unit input 1180, and into a filtering unit 1060. The filtering unit 1060 is configured to remove post-process solids from the slurry leaving behind the saturated solvent comprising solvent and alpha acids. A first filtering unit output 1190 is connected to a first distilling input 1200 of a distilling unit (shown in FIG. 1D). The filtering unit 1060 further comprises a second filtering unit output 1195 for the removal of post-process solids from the system for disposal.
[0034] Certain embodiments, shown in FIG. 2A, comprise a dehydrator 1030, a mixing mechanism 1050, a distilling mechanism 1070, and a drying apparatus 1400. Such embodiments are directed toward the extraction of alpha-acids from post-process solids.
[0035] In certain embodiments, as shown in FIG. 2B, a mixing mechanism 1050 comprises a mixing motor 1051 and mixing element 1052 extending into a mixing reservoir 1053. Within the mixing reservoir 1053, solvent may be combined with post-process solids to create a slurry. Once combined, the slurry passes through a valve 1060 to a dehydrator 1030. The dehydrator 1030 separates post-process solids from a solution. The solution comprises solvent and dissolved alpha acids. In certain embodiments, a dehydrator 1030 comprises a filtering unit 1180 allowing separation of particulate matter which may remain in the solution after passing through the dehydrator 1030. In such embodiments, the liquid content is filtered by the filtering unit 1180 and directed into a solution reservoir 1015. The post process-solids exit a dehydrator output 1120 and deposited into a post-process solid holding chamber 1016.
[0036] Certain embodiments of the present invention, shown in FIG. 1D and FIG. 2C, comprise a distilling unit 1070 for the separation of a solvent or other liquid from a solution. In certain embodiments, a solution comprising water and alpha-acids, from of the dehydrator 1030 of FIG. 2B, is added to the distilling unit 1070, of FIG. 2C, for the separation of a solvent from the solution. A distilling unit as shown in FIG. 2C further comprises a distilling chamber 1210, a heating element 1220, a still head 1230, a solvent recapture output 1285. After the distillation process, the captured solvent is directed through the solvent recapture output 1285 into a solvent recapture reservoir 1080, and a solution comprising water and the alpha acids are output to a holding vessel 1320.
[0037] It will be appreciated that a distilling unit 1070 as shown in FIG. 1D and FIG. 2C may comprise distilling units known to those skilled in the art such as, but not limited to, U.S. Pat. No. 1,833,717 to Laird, incorporated by reference in its entirety for all purposes. It will be further appreciated that the distilling unit of the present invention typically employs simple batch distillation methods, but may alternatively use other distillation methods such as, but not limited to fractional distillation, steam distillation, or vacuum distillation.
[0038] In certain embodiments of the present invention, a distilling unit as shown in FIG. 1D, separates a solvent from a solution comprising solvent and water. The distilling unit 1070 comprises a distilling chamber 1210 and a heating element 1220. A solution contained in the distilling chamber 1210 is heated by the heating element 1220 to heat the solution to, or exceeding, a boiling point of the solvent, but below the boiling point of water. The solvent transitions to a vapor state and proceeds upward into a still head 1230. The still head 1230 further comprises a condensate capture feature 1240 and a condensing unit 1250. The condensing unit 1250 cools the temperature of the still head 1230 to a level where the solvent entering the still head 1230 condenses and falls toward the condensate capture feature 1240. The condensate capture feature 1240 directs the condensed solvent toward a first distilling unit output 1265 of the distilling unit 1070, and into a first chiller unit input 1270 of a chiller unit 1260. The chiller unit 1260 provides cooling for the captured solvent. The solvent then passes through a first chiller unit output 1280 and into a solvent recapture reservoir input 1285 of a solvent recapture reservoir 1080 for the recapture and reuse of the solvent. It will be appreciated that a cooling fluid or refrigerant is cycled through such features as a chiller unit 1260 or a condensing unit 1250 to provide cooling action to the process as disclosed. It will be appreciated that cooling fluid may comprise a gas such as air, nitrogen, hydrogen, or other cooling fluid gasses known to those skilled in the art, or a liquid such as water, glycol, oils, Freon, or other cooling fluids known to those skilled in the art.
[0039] In certain embodiments as seen in FIG. 1D, cooling fluid is supplied to the condensing unit 1250 through a first condensing unit input 1290. The cooling fluid exits the condensing unit 1250 through the first condensing unit output 1300 and into a second chiller unit input 1305 of the chiller unit. The cooling fluid then passes through the chiller unit 1260 to cool the captured condensed solvent. The cooling fluid then exits the chiller unit 1260 through a second chiller unit output 1310. It will be appreciated that in other embodiments, a chiller unit 1260 and condensing unit 1250 may have independent cooling fluid supplies. It will be appreciated that a condensing unit 1250 and chiller unit 1260 both act to cool a gaseous or liquid state material. It will be further appreciated that a chiller unit 1260 and condensing unit 1250 may use cooling strategies known to those skilled in the art including, but not limited to, cooling strategies used by a Liebig condenser, a West condenser, an Allihn condenser, a Davies condenser, a Graham condenser, a coil condenser, a Dimroth condenser, a spiral condenser or Friedrichs condenser. Once the solution has been distilled, the remaining water and alpha acid crystals are held in the holding vessel 1320. The mixture of water and alpha acids may then be transferred to a drying apparatus.
[0040] Certain embodiments, as shown in FIG. 1D, comprise a first distilling unit input 1200 and a second distilling input 1205 through which a solution and additional water may be added. This allows for the addition of water or fluids, gasses or materials to the solution held in the holding vessel 1320, prior to or following the distillation process.
[0041] Certain embodiments of the present invention comprise a drying apparatus 1400, as shown in FIG. 2D. A drying apparatus 1400 comprises a spray dryer having a pump 1410, a nozzle 1420, a drying chamber 1430, and a first collection vessel 1440. In such embodiments, a pump 1410 delivers a solution comprising a solvent and a solute, such as water and alpha-acid crystals to the nozzle 1420. The pump 1410 draws the solution from a holding vessel 1320 through a pump inlet line 1417. The solution passes through the pump 1410, then through a nozzle inlet line 1419 to the nozzle 1420. The nozzle 1420, generates small droplets to increase the surface area of the solution. Certain embodiments comprise a nozzle 1420 having a spinning functionality wherein the nozzle 1420 provides a 360-degree delivery of droplets to more equally distribute droplets throughout the drying chamber 1430. The drying apparatus 1400 further comprises a system air-pump 1450, an air-inlet 1460, and an air-heater 1470. The system air-pump 1450 creates a vacuum to draw air through the air-inlet 1460 and across an air-heater 1470. It will be appreciated an air-pump 1450 may operate to provide a negative or positive pressure air-flow. For example, the air-inlet 1460 and air-heater 1470 can provide a heated airflow in a cyclonic motion within the drying chamber 1430. When the solution droplets exiting the nozzle 1420 are exposed to the heated airflow, the solvent evaporates and the solute precipitates out of solution. The precipitated solute, such as alpha-acid crystals, are deposited on an internal surface 1480 within the drying chamber 1430 as well as in a first collection vessel 1440 located at the bottom of the drying chamber 1430. The air-flow, comprising the evaporated solvent, is then carried out of the drying chamber 1430 through a drying chamber outlet 1435 leaving behind the precipitated solute. It will be appreciated that a pump 1410 may comprise any fluid pump for the transmission of fluids from one volume to another including non-volatile pumps, peristaltic pumps, or other pumps known to those skilled in the art.
[0042] Certain embodiments as shown in FIG. 2D, comprise a cyclonic separator 1490. The cyclonic separator 1490 is disposed between the system air-pump 1450 and the drying chamber 1430 to capture solute crystals, which may be carried out of the drying chamber 1430 by air-flow due to their small size. The cyclonic separator 1490 comprises a second collection vessel 1441 wherein solutes crystals, carried out of the drying chamber 1430, are deposited.
[0043] Certain embodiments of the present invention, as shown in FIG. 3, comprise a method 2000 for the extraction of alpha-acids from post-process solids comprising the steps of combining 2020 post-process solids with a solvent, mixing 2030 the combination of the post-process solids with solvent to create a substantially homogenous slurry, separating 2040 a solution from the slurry, diluting 2050 the solution, distilling 2060 the solution, cooling 2080 the solution, and drying 2090 the solution prior to collecting 2100 of dried alpha-acid crystals. Certain embodiments of the present invention comprise a step of packaging 2110 following the step of collecting 2100 of dried alpha acids. It will be appreciated that after steps such as separating 2040 a solution, or distilling 2050 the solution, it may be desired to allow the settling 2070 of a solution for a predetermined period of time. to remove unwanted solids or capture solute, such as alpha-acid crystals, which have precipitated out of solution. Certain embodiments of the present invention comprise allowing a solution to settle for 4-8 hours. In certain embodiments of the present invention, it may be desired for post-process solids to undergo a dehydrating 2010 step prior to the combining 2020 of post-process solids with a solvent.
[0044] Certain embodiments comprise combining 2020 a solvent with post-process solids prior to mixing 2030 post-process solids with a solvent. The mixing 2030 helps maximize the dissolving alpha-acids of the post-process solids into solution. Mixing 2030 the combination of post-process solids and solvent creates a slurry comprising post-process solids and a solution. Once mixing 2030 is complete, the solution is separated, 2040, from the slurry, which separates the liquid portion of the slurry from the solid post-process solids. Once the solution is separated from the slurry, the solid portion of the slurry can be discarded. The solution then undergoes diluting 2050 in preparation for distilling 2060. In certain embodiments, dilution 2050 comprises diluting the solution to be 20% water, by volume. It will be appreciated that if a solution comprises water content above 20%, diluting may be omitted.
[0045] In certain embodiments as shown in FIG. 3, the solution is brought to a temperature exceeding the boiling temperature of the solvent but not exceeding the boiling temperature of the water. The solvent typically has a lower boiling point than that of water. It will be appreciated that the boiling point of a liquid is the temperature at which the transition from liquid to gas, or gas to liquid, occurs at a given pressure. It will be further appreciated that the boiling point of a given liquid changes dependent upon atmospheric pressure.
[0046] Once the solvent is separated from the solution, the resulting solution comprises alpha-acids and water. Some alpha-acids may precipitate out of solution during the cooling 2080, as cooling of the solution lowers the saturation limit of the solvent. The solution then undergoes a settling 2070. Settling 2070 allows alpha-acids that have precipitated out of solution to settle out of suspension within the remaining solution. Once settling 2070 is complete, the solution undergoes drying 2090 to remove the water content and dry the remaining alpha-acid crystals in preparation for the collecting step.
[0047] In certain embodiments, drying 2090 comprises pressurized delivery of a solution through a spray nozzle in a dry environment to evaporate the water from the solution, leaving crystalline alpha-acids. The spray nozzle, is directed into a collection vessel where the crystalline alpha-acids are deposited along the internal surfaces of the collection vessel. In such embodiments, collecting 2100 may involve the scraping of crystalline alpha acids from the collection vessel walls for packaging. Scraping of the crystalline alpha-acids can be performed with a variety of different objects and materials, but is typically performed with a food grade, durable and flexible product such as polytetrafluoroethylene (PTFE) sheet material. Once the crystalline alpha-acids are collected, the crystalline alpha-acids are packaged. Packaging 2110 generally seals the crystalline alpha-acids from the ambient environment to prevent unwanted exposure to factors such as moisture.
[0048] While various embodiments the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention. Further, the inventions described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of including, comprising, or adding and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items.
