Compositions and Methods for GRAS Compliant Cleaners for Ethanol Production Equipment

Abstract

The present technology relates to various cleaning compositions and their methods of use in industrial facilities such as ethanol and biofuel producing vessels. Cleaning compositions according to the present technology may be Generally Recognized As Safe (GRAS) as designated by the U.S. Food and Drug Administration (FDA). The cleaning compositions of the present technology may effectively remove biofilm buildup and/or spent grain residue from industrial fermentation vessels and associated apparatus. Various embodiments of the cleaning composition may comprise various surfactants, chelators, acids, bases, and/or defoamers. Some embodiments of the cleaning composition may comprise a gluconate, a glucoside, a strong acid or base, and/or a defoamer.

Claims

1. A cleaning composition for mixing with a strong acid or strong base comprising: water; a gluconate; and a polyglucoside; wherein the cleaning composition reduces a surface tension of the strong acid or strong base.

2. The cleaning composition of claim 1, further comprising a defoamer.

3. The cleaning composition of claim 2, wherein the defoamer comprises at least one of silica, dimethyl silicone polymer, and white mineral oil.

4. The cleaning composition of claim 2, wherein the defoamer is combined with the cleaning solution in a ratio of approximately one part defoamer for every approximately 10,000 parts cleaning solution.

5. The cleaning composition of claim 1, wherein the gluconate is a sodium salt of gluconic acid.

6. The cleaning composition of claim 5, wherein the cleaning composition contains approximately 4% to approximately 6% by weight of gluconic acid.

7. The cleaning composition of claim 1, wherein the polyglucoside is at least one of caprylyl glucoside and decyl glucoside.

8. The cleaning composition of claim 7, wherein the cleaning composition contains approximately 0.5% to approximately 2% by weight of at least one of caprylyl glucoside and decyl glucoside.

9. A cleaning composition comprising: at least one of gluconic acid and a sodium salt of gluconic acid; at least one of caprylyl glucoside and decyl glucoside; and a strong acid or a strong base, wherein the cleaning composition reduces a surface tension of a biofilm.

10. The cleaning composition of claim 9, wherein the strong base is sodium hydroxide.

11. The cleaning composition of claim 9, wherein the strong base is potassium hydroxide.

12. The cleaning composition of claim 9, wherein the strong acid is phosphoric acid.

13. The cleaning composition of claim 9, further comprising a defoamer.

14. The cleaning composition of claim 13, wherein the defoamer comprises at least one of silica, dimethyl silicone polymer, and white mineral oil.

15. The cleaning composition of claim 13, wherein the defoamer is combined with the cleaning solution in a ratio of approximately one part defoamer for every approximately 10,000 parts cleaning solution.

16. The cleaning composition of claim 9, wherein the cleaning composition contains approximately 4% to approximately 6% by weight of the sodium salt of the gluconic acid.

17. The cleaning composition of claim 9, wherein the cleaning composition contains approximately 0.5% to approximately 2% by weight of the at least one of the caprylyl glucoside and decyl glucoside.

18. The cleaning composition of claim 9, wherein the cleaning composition contains approximately 45% by weight sodium hydroxide.

19. A method of cleaning an interior component of a vessel comprising the steps of: preparing a cleaning composition by mixing gluconic acid, a polyglucoside, and water, mixing a solution of approximately 50% by weight sodium hydroxide in water with the mixture of the gluconic acid, polyglucoside, and water, to a final concentration of approximately 45% by weight sodium hydroxide; and applying the cleaning composition to the interior component of the vessel to remove a biofilm attached to the interior component and cause its removal from the interior component of the vessel.

20. The method of claim 19, further comprising the step of adding a defoamer to the interior component of the vessel after adding the cleaning composition to the vessel.

21. The method of claim 19, wherein the cleaning composition is made by: first adding water to a container to approximately 49% by weight of the first component; second adding an amount of an approximately 50% gluconic acid solution in water to the water in the container such that the cleaning composition contains approximately 25% gluconic acid; third adding polyglucoside to the water and gluconic acid mixture such that the cleaning composition contains approximately 1% by weight polyglucoside.

22. The method of claim 19, wherein the cleaning composition is made by: adding water to a container to approximately 4.9% by weight of the first component; adding an amount of an approximately 50% gluconic acid solution in water to the water in the container such that the first component contains approximately 5% gluconic acid; adding sodium hydroxide to the water and gluconic acid mixture such that the first component contains approximately 45% by weight sodium hydroxide; allowing ammonia to vent from the mixture of water, gluconic acid, and sodium hydroxide; and adding polyglucoside to the mixture of water, gluconic acid, and sodium hydroxide mixture such that the first component contains approximately 0.1% by weight polyglucoside.

23. The method of claim 19, wherein the sodium hydroxide is added to the cleaning composition prior to applying the cleaning composition with the sodium hydroxide to an interior component of the vessel.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0008] A more complete understanding of the present technology may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures.

[0009] Elements and steps in the figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence or scale. For example, steps that may be performed concurrently or in different order are illustrated in the figures help to improve understanding of embodiments of the present technology.

[0010] The figures described are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. Various aspects of the present technology may be more fully understood from the detailed description and the accompanying drawing figures, wherein:

[0011] FIG. 1 is a flow chart for the preparation of an exemplary cleaning composition; and

[0012] FIG. 2 is a flow chart for the preparation of an exemplary cleaning composition mixed with sodium hydroxide.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0013] The present technology may be described herein in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components configured to perform the specified functions and achieve the various results. For example, the present technology may employ various surfactants, acids, bases, defoamers, storage facilities, and the like, which may carry out a variety of functions. In addition, the present technology may be practiced in conjunction with any number of devices used to mix components and/or apparatus to apply the components to a fermentation system.

[0014] The present technology relates to various cleaning compositions and their methods of use in interior components of various industrial vessels. The vessels may be any industrial ethanol production facilities such as for producing biofuels, dairy production facilities, and any other vessels that require cleaning with compositions that are Generally Recognized as Safe (GRAS) under the U.S. Food and Drug Administration (FDA) rules due to their use for producing human and animal food products. The GRAS designation of the cleaning composition indicates that it is a chemical or substance added to food that is considered safe for its intended use according to expert opinion. The GRAS designation provides an exemption from the Federal Food, Drug, and Cosmetic Act (FFDCA) food additive tolerance requirements.

[0015] The cleaning composition of the present technology may be used in any interior component of the vessel to remove residue and biofilms that build up inside the interior components during use of the vessel. For example, the interior components may be the interior walls of ethanol fermentation bioreactors, grain grinders, and distillation vessels as well as associated pumps, fluid lines, tubes, and pipes. Similarly, the interior components may be the interior walls of various dairy processing vessels, such as dairy holding tanks and pasteurization vats and associated tubes through which milk is pumped.

[0016] The cleaning compositions of the present technology may effectively remove residue from biofilm buildup and/or spent grain residue from the interior components of the vessels. Bacterial infections and build-up from calcium carbonate, calcium oxalate, and iron in vessels due to poor cleaning causes reductions in ethanol yield and consequent financial losses.

[0017] The cleaning composition according to various aspects of the present technology may comprise a gluconate, a glucoside, distilled (DI) water, a strong acid or base, and/or a defoamer. In various aspects, the gluconate and polyglucoside of the cleaning composition may reduce the surface tension of the strong acid or strong base, such as sodium hydroxide, causing the cleaning composition to more effectively penetrate and dislodge biofilms and residues it encounters in the interior components of vessels to aid in their removal. The cleaning composition may be low foaming, reducing or preventing the need to add extraneous defoaming solutions and additional rinse steps.

[0018] Various embodiments of the cleaning solution may utilize a strong acid or base. For example, the cleaning solution may comprise sodium hydroxide and/or, potassium hydroxide. In some embodiments, the cleaning solution may comprise phosphoric acid. Sodium hydroxide has been GRAS approved under CAS Reg. No. 1310-73-2. In some embodiments, a stock solution of 50% by weight of sodium hydroxide, diaphragm or membrane grade, may be used in the cleaning solution.

[0019] Various embodiments of the cleaning composition may comprise the surfactant gluconate. The gluconate may comprise a salt of gluconic acid such as sodium gluconate. Various exemplary stock formulations of the sodium gluconate may be a dry powder or a solution of 60% or 70% by weight sodium gluconate. In some embodiments, the gluconate may be gluconic acid, such as a 50% by weight solution of gluconic acid. Gluconic acid is an organic compound of the molecular formula C.sub.6H.sub.12O.sub.7 and the structural formula HOCH.sub.2(CHOH).sub.4COOH and may act as a chelant and/or dispersant. Sodium gluconate is GRAS certified under 21 C.F.R. 182.6757. In some embodiments, the cleaning composition may comprise approximately 4% to approximately a 6% by weight of gluconic acid. In some embodiments, the cleaning composition may comprise up to approximately 5% by weight gluconic acid. In one embodiment, the cleaning composition may comprise approximately 5% by weight gluconic acid. Higher concentrations of the gluconic acid may be needed when used with water with a high hardness, such as over 25 grains per gallon (gpg).

[0020] Various embodiments of the present technology may also utilize a polyglucoside. In some embodiments, the polyglucoside may increase solubility of components of the gluconic acid, increasing its potency as a cleaner. In some embodiments, the polyglucoside may act as a surfactant to reduce surface tension of the caustic soda so less caustic soda and/or cleaning solution needs to be used to clean the same surface area.

[0021] In one embodiment, the glucoside may comprise caprylyl glucoside and/or decyl glucoside. For example, in one embodiment the glucoside may comprise a mixture of caprylyl glucoside and decyl glucoside provided in the product Glucopon 215 UP (BASF Home Care and Industrial Ingredients). Glucopon 215 UP has been concluded to be GRAS for the application of cleaning vegetables, poultry, etc. In some embodiments, the polyglucoside may exhibit the tendency to foam. In various embodiments, the cleaning composition may comprise up to approximately 0.5% to approximately 2% by weight Glucopon 215 UP. For example, in some embodiments, the cleaning composition may comprise up to approximately 1% by weight Glucopon 215 UP.

[0022] In some embodiments, the cleaning composition may further comprise or be used in conjunction with a defoamer. The defoamer may be used to reduce foaming of the polyglucoside inside the interior components of the vessel. For example, the cleaning composition may be added to the interior components of the vessel for cleaning, followed by the addition of the defoamer to the vessel separately from the cleaning composition. In some embodiments, the defoamer may be added to the cleaning composition prior to the application of the cleaning composition to the vessel. Some defoamers may be hydrophobic and unstable when added to the cleaning composition, necessitating the separate use of the defoamer in the vessel. In various embodiments, the defoamer may comprise any suitable GRAS designated chemical that prevents foaming or impedes its formation. In various embodiments, the defoamer may comprise silica, dimethyl silicone polymer, and/or white mineral oil. For example, in one embodiment, the defoamer may comprise Tramfloc 1174 (Tramfloc, Inc., Spring, Texas). In various embodiments, the defoamer may be added to the cleaning composition in a ratio of approximately one part defoamer for every approximately 10,000 parts complete solution.

[0023] Referring to FIG. 1, a method of preparing the cleaning composition 100 may comprise adding distilled (DI) water to a container to approximately 49% by weight of the cleaning composition 100 (105), then adding a stock solution of approximately 50% gluconic acid to the DI water to approximately 50% by weight of the cleaning composition 100 (110 and 115). The Glucopon 215 UP (polyglucoside) may then be added to the gluconic acid and DI water mixture to approximately 1% by weight of the cleaning composition 100 (120 and 125). For example, in some embodiments, the cleaning composition 100 may be prepared according to the formula:

TABLE-US-00001 TABLE 1 Cleaning Composition 100 Component % by weight DI Water 49 Gluconic Acid 50% 50 Glucopon 215 UP 1 Total 100

[0024] The cleaning composition 100 may be beneficially prepared for transport to the industrial facility, such as an ethanol plant, since due to its low propensity to foam while being disturbed as it is transported. Once the cleaning composition 100 arrives at the industrial facility, it may be mixed with the sodium hydroxide, such as a stock solution of 50% NaOH, to form the usable cleaning composition. In another embodiment, the sodium hydroxide may be added to the cleaning composition 100 prior to transportation to the industrial facility.

[0025] Referring to FIG. 2, in some embodiments, a cleaning composition 200 (which constitutes the useable cleaning composition) may be prepared by adding DI water to a container to approximately 4.9% by weight of the cleaning composition 200 (205), then adding a solution of 50% gluconic acid to the DI water to approximately 5% by weight of the cleaning composition 200 (210 and 215). The sodium hydroxide, such as using a stock solution of 50% sodium hydroxide, may be added to the gluconic acid and DI water mixture to approximately 90% by weight of the cleaning composition 200 (220 and 225). Ammonia may vent from the mixture. The Glucopon 215 UP (polyglucoside) may then be added to the gluconic acid, DI water, and sodium hydroxide mixture to approximately 0.1% by weight of the cleaning composition 200 (230 and 235). For example, the cleaning composition 200 may be prepared according to the formula:

TABLE-US-00002 TABLE 2 Cleaning Composition 200 Component % by weight DI Water 4.9 Gluconic Acid (50% stock) 5 Glucopon 215 UP 0.1 Sodium Hydroxide (50% stock) 90 Total 100

[0026] Various embodiments of the cleaning composition exhibit various surface tensions. Surface tension is a measurement of the attraction of the surface of a liquid to another surface. Surfactants, such as gluconic acid, lower the surface tension of the cleaning composition to allow it to spread and penetrate into the biofilms and residues in the interior components of the vessel, breaking them down, and creating an emulsion to wash them away. The lower the surface tension, the more the cleaning solution will penetrate the contaminants in the vessel.

[0027] The surface tension of various dilutions of the cleaning composition were measured using a Wilhelmy plate method on a Krus K100 processor Tensiometer:

TABLE-US-00003 TABLE 3 Surface Tension Measurements % by weight % by weight Average Surface Tension cleaning composition Glucopon 215 UP of 2 Replicates (nM/m) 2 5 29.96 2 10 28.32 2 20 28.25 1 5 30.81 1 10 29.95 1 20 28.48 0.5 5 37.91 0.5 10 34.90 0.5 20 29.73

[0028] The surface tension of cleaning compositions comprising 45% distilled water, 25% by weight gluconic acid, and one of 5%, 10%, and 20% by weight of the polyglucoside, Glucopon 215 UP, was measured. Each of the cleaning compositions was diluted to 2%, 1%, and 0.5% by weight in distilled water. The surface tension data demonstrated that use of approximately 10% Glucopon 215 UP in the cleaning composition without sodium hydroxide, which translates to approximately 1% Glucopon 215 UP in the cleaning composition with sodium hydroxide, provides a beneficially low surface tension.

[0029] In the foregoing description, the technology has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the scope of the present technology as set forth. The description is to be regarded in an illustrative manner, rather than a restrictive one and all such modifications are intended to be included within the scope of the present technology. Accordingly, the scope of the technology should be determined by the generic embodiments described and their legal equivalents rather than by merely the specific examples described above. For example, the steps recited in any method or process embodiment may be executed in any appropriate order and are not limited to the explicit order presented in the specific examples. Additionally, the components and/or elements recited in any system embodiment may be combined in a variety of permutations to produce substantially the same result as the present technology and are accordingly not limited to the specific configuration recited in the specific examples.

[0030] Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments. Any benefit, advantage, solution to problems or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced, however, is not to be construed as a critical, required or essential feature or component.

[0031] The terms comprises, comprising, or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present technology, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same.

[0032] The present technology has been described above with reference to an exemplary embodiment. However, changes and modifications may be made to the exemplary embodiment without departing from the scope of the present technology. These and other changes or modifications are intended to be included within the scope of the present technology.