Polyelectrolyte flocculation of grain stillage for improved clarification and water recovery within bioethanol production facilities

Polyelectrolytes were investigated for flocculation of a corn whole stillage stream to improve solid–liquid clarification operations and reduce downstream utility requirements for evaporation and drying within a bioethanol process. Despite a negative zeta potential for the stillage solids, an anionic polyelectrolyte was found to provide the best flocculation. At the optimal dosage of 1.1 mg polymer/g dry suspended solids, an anionic flocculant provided a clarified stream with only 0.15% w/w suspended solids (equivalent to a total dissolved solid to total suspended solid ratio greater than 40, and a viscosity reduction of 39% compared to an unflocculated “clarified” stream). The resulting solids cake had greater than 40% w/w solids, and more than 80% water recovery was found in the clarified stream. Addition of flocculant improved filtration flux by six fold and/or would allow for up to a 4-times higher flow rate if using a decanting centrifuge for clarification of corn stillage.