U.S. patent application number 12/533893 was filed with the patent office on 2010-05-06 for system and process for starch production.
This patent application is currently assigned to H R D CORPORATION. Invention is credited to Rayford G. Anthony, Ebrahim Bagherzadeh, Gregory Borsinger, Abbas Hassan, Aziz Hassan.
Application Number | 20100111786 12/533893 |
Document ID | / |
Family ID | 40161382 |
Filed Date | 2010-05-06 |
United States Patent
Application |
20100111786 |
Kind Code |
A1 |
Hassan; Abbas ; et
al. |
May 6, 2010 |
SYSTEM AND PROCESS FOR STARCH PRODUCTION
Abstract
Use of a high shear mechanical device in a process for
production of starch by hydration and disruption of corn kernel
particles in the presence of sulfur dioxide or bisulfite ions makes
possible a decrease in mass transfer limitations, thereby enhancing
starch production. A system for production of starch is also
provided in which a high shear mixing device is configured to
receive an aqueous corn slurry from a pump that is disposed between
the reactor and a gaseous sulfur dioxide inlet of the high shear
mixing device. The high shear mixing device is also configured to
generate a fine dispersion of sulfur dioxide bubbles and small corn
particles in the slurry. A reactor is configured to receive the
output from the high shear mixing device and to provide for starch
production.
Inventors: |
Hassan; Abbas; (Sugar Land,
TX) ; Bagherzadeh; Ebrahim; (Sugar Land, TX) ;
Anthony; Rayford G.; (College Station, TX) ;
Borsinger; Gregory; (Chatham, NJ) ; Hassan; Aziz;
(Sugar Land, TX) |
Correspondence
Address: |
CONLEY ROSE, P.C.;David A. Rose
P. O. BOX 3267
HOUSTON
TX
77253-3267
US
|
Assignee: |
H R D CORPORATION
Houston
TX
|
Family ID: |
40161382 |
Appl. No.: |
12/533893 |
Filed: |
July 31, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12142120 |
Jun 19, 2008 |
|
|
|
12533893 |
|
|
|
|
60946471 |
Jun 27, 2007 |
|
|
|
Current U.S.
Class: |
422/225 ;
422/232; 422/234 |
Current CPC
Class: |
C08B 30/04 20130101;
C08B 30/044 20130101; B01F 13/1013 20130101; B01F 13/1016 20130101;
B01F 7/00766 20130101 |
Class at
Publication: |
422/225 ;
422/234; 422/232 |
International
Class: |
C08B 31/00 20060101
C08B031/00; B01J 19/18 20060101 B01J019/18; B01F 3/06 20060101
B01F003/06 |
Claims
1. A system for production of starch, comprising; a high shear
mixing device having a corn slurry inlet, a sulfur dioxide inlet
and a dispersion outlet, said mixing device being configured to
produce a dispersion of corn kernel particles and submicron-sized
sulfur dioxide bubbles and in an aqueous medium; a reactor
configured for receiving said dispersion, and having a slurry
outlet and a product outlet; a pump disposed between said slurry
outlet and the slurry inlet of said high shear mixing device; and a
starch-gluten separator configured for receiving at least a portion
of said product and separating said starch.
2. The system of claim 1, wherein said high shear mixing device
comprises a rotor-stator set having a tip, wherein said device is
configured to produce a rotor tip speed of at least 22.9 m/sec.
3. The system of claim 1, wherein said high shear mixing device
comprises a rotor-stator set having a tip, wherein said device is
configured to produce a rotor tip speed of at least 40 m/sec.
4. The system of claim 1 wherein the reactor comprises a batch
reactor.
5. The system of claim 1 wherein the reactor comprises a
continuously or semi-continuously stirred tank.
6. The system of claim 1 wherein said high shear mixing device
comprises a first high shear mixing device, and the system further
comprises at least one additional high shear mixing device in
series flow alignment following said first mixer, said additional
devices having progressively higher shear rates.
7. The system of claim 6 further comprising a protein separator and
oil separator following at least one said additional mixer.
8. The system of claim 1 wherein said high shear mixing device
comprises at least one generator comprising a rotor and a
complementarily-shaped stator.
9. The system of claim 8 wherein said high shear mixing device is
operable to provide a shear rate of at least 20,000 s.sup.-1,
wherein the shear rate is defined as the tip speed divided by the
shear gap, and wherein the tip speed is defined as .pi.Dn, where D
is the diameter of the at least one rotor and n is the frequency of
revolution.
10. The system of claim 8 comprising at least two generators.
11. The system of claim 10 wherein at least one of the at least two
generators provides a shear rate that is greater than the shear
rate provided by another of the at least two generators, wherein
the shear rate is defined as the tip speed divided by the shear
gap, and wherein the tip speed is defined as .pi.Dn, where D is the
diameter of the at least one rotor and n is the frequency of
revolution.
12. The system of claim 1 further comprising a grinder fluidly
connected with the reactor, wherein said grinder is configured for
cracking corn kernels and loosening hulls of the corn kernels to
provide a corn grist of a desired particle size.
13. The system of claim 12 further comprising a germ and hull
separator positioned between the reactor and the grinder, wherein
said germ and hull separator is configured to separate the corn
hulls from the corn grist.
14. The system of claim 1 wherein said reactor further comprises an
inlet for introducing water, bisulfite solution, or a combination
thereof to said reactor.
15. The system of claim 1 further comprising a screening assembly
fluidly connected with the product outlet of the reactor, wherein
the screening assembly is configured for separating fiber from
starch and gluten.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application which claims
the benefit under 35 U.S.C. 121 of U.S. patent application Ser. No.
12/142,120, filed Jun. 19, 2008, which claims the benefit under 35
U.S.C. .sctn.119(e) of U.S. Provisional Patent Application No.
60/946,471, filed Jun. 27, 2007, the disclosures of each of which
are hereby incorporated herein by reference
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
TECHNICAL FIELD
[0003] The present invention generally relates to the production of
starch from corn, and more particularly to apparatus and methods
for producing starch from corn using sulfur dioxide or bisulfite
treatment. Still more particularly, the invention relates to such
apparatus and methods which employ high shear mixing to reduce mass
transfer limitations.
BACKGROUND
[0004] Starch is a mainstay of our food, pharmaceutical, paper,
chemical, textile, cosmetic, and energy industries. It serves as a
raw material in the manufacture of such basic consumer necessities
as paper and textiles, and is also used in sizing, surface coating
and adhesives. Corn starches and their derivatives are also used in
a variety of other applications, including the manufacture of
"drilling muds" that are used to cool oil well drilling bits, and
in flocculating agents, anti-caking agents, mold-release agents,
dusting powder and thickening agents. A developing market for corn
starch is for use as a feedstock for production of a number of
industrial chemicals and plastics that heretofore relied on
petroleum-derived feedstocks. As the world's petroleum supply
dwindles or becomes less reliable, the importance of an abundant
renewable natural source of raw material such as corn starch
becomes increasingly attractive.
[0005] The wet milling process is traditionally used to separate
corn into its primary components of starch, germ, fiber and
protein. The wet milling processes, for example, generally comprise
four basic stages: steeping, germ separation, grinding/screening,
and starch-gluten separation. After inspection and cleaning, corn
kernels are steeped in a dilute aqueous SO.sub.2 solution for 1 to
2 days to soften the corn kernels and begin breaking disulfide
bonds in the protein matrix that holds the proteins and starch
together. The next step in the process involves a coarse grind to
separate the germ from the rest of the kernel. The resulting
slurry, consisting of fiber, starch and protein, is finely ground
and screened to separate the fiber from the starch and protein. The
starch is separated from the remaining slurry in hydrocyclones. The
starch can then can be used for making drilling mud, or can be
further processed for a variety of other applications.
[0006] The steeping operation is a diffusion limited process.
During the 24-48 hour soak, the water and SO.sub.2 diffuse into the
corn kernel through the base end of the tip cap, and then move
through the pericarp to the kernel crown and into the endosperm.
The absorbed SO.sub.2 cleaves the disulfide bonds in the protein
matrix that encapsulates the starch granules, dispersing the
protein matrix, and enhancing starch release. The time for
penetration of SO.sub.2 into the endosperm and its reaction time
with the protein matrix makes steeping a very time consuming
operation in the corn wet-milling process. Steeping times shorter
than 24 hours result in poor starch yields and loss of starch to
fiber and protein fractions. Steeping is also one of the most
capital and energy intensive parts of the corn wet-milling process.
Reducing steep time would decrease energy cost, increase plant
capacity and reduce the capital cost involved in construction of
new corn wet-milling plants.
[0007] Several mechanical and chemical approaches have been
investigated to decrease steep time while maintaining product
yields. Such processes typically require costly modifications of
existing facilities or pretreatment of kernels, resulting in
increased pollution or increased energy use. It has been said that
the development of a processing procedure that could reduce the
steep time and decrease or eliminate the use of chemicals such as
sulfur dioxide would have a significant impact on the corn
wet-milling industry.
[0008] Processes in which dehulled and degermed dry-milled corn is
mixed with water for a period of not more than 4 hours at ambient
temperature to form an aqueous slurry have also been explored. In
some cases, the slurry is treated with alkali, and then subjected
to certain high intensity mixing to yield a high-quality starch.
Sodium sulfite may be present in the alkali-containing slurry.
Existing processes and production facilities for producing starch
from corn are typically subject to various constraints including
mass flow limitations, product yield, plant size and energy
consumption. Accordingly, there is continued interest in the
development of ways to improve the selectivity and yield of starch
from corn.
SUMMARY
[0009] A high shear system and process for accelerating starch
production from corn is disclosed. Some embodiments of the high
shear process make possible a reduction in mass transfer
limitations, thereby increasing the rate of hydration of protein
matrix and release of starch, enabling a reduction in processing
time and an increase in product yield. In accordance with certain
embodiments, a process is provided that offers more optimal time,
temperature and pressure conditions than are typical of other
starch production processes. Embodiments of the disclosed process
employs an external high shear mechanical reactor to provide
enhanced time, temperature and pressure conditions resulting in
accelerated release of starch granules and increased yield of
starch.
[0010] In accordance with certain embodiments, a method for
producing starch is provided which comprises obtaining a high shear
mixing device; forming in the high shear mixing device a high shear
mixture comprising dehulled and degermed corn kernel particles,
sulfur dioxide, and an aqueous medium, wherein the high shear
mixture comprises submicron-sized sulfur dioxide-containing bubbles
and/or submicron-sized corn kernel particles dispersed in the
aqueous medium; and causing the extraction of starch from the
dispersed particles and solubilization of the starch in the aqueous
medium.
[0011] In accordance with certain other embodiments, a system for
production of starch is provided which comprises a high shear
mixing device having a corn slurry inlet, a sulfur dioxide inlet
and a dispersion outlet, wherein the mixing device is configured to
produce a dispersion of corn kernel particles and submicron-sized
sulfur dioxide bubbles and in an aqueous medium; a reactor
configured for receiving the dispersion, and having a slurry outlet
and a product outlet; a pump disposed between the slurry outlet and
the slurry inlet of the high shear mixing device; and a
starch-gluten separator configured for receiving the
starch-containing product and separating the starch. These and
other embodiments and potential advantages will be apparent in the
following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a process flow diagram for a high shear process
for production of starch, in accordance with an embodiment of the
invention.
[0013] FIG. 2 is a longitudinal cross-section view of a multi-stage
high shear device, as employed in an embodiment of the system of
FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] An improved process and system for the production of starch
by modified corn wet-milling and starch extraction employs an
external high shear mixer to provide rapid mixing and intimate
contacting of corn grit with an aqueous SO.sub.2 solution in a
controlled environment in the high shear mixer. The high shear
device reduces mass transfer limitations in the extraction process
and thus increases the overall processing rate by speeding
hydration of the protein matrix that encapsulates the starch, and
causing the release of starch globules. The enhanced contacting of
the corn particles with the SO.sub.2 solution in a highly dispersed
state potentially allows a reduced amount of SO.sub.2 to be used in
embodiments of the process without sacrificing quality or quantity
of the starch product.
[0015] Chemical reactions involving liquids, gases and solids rely
on the laws of kinetics that involve time, temperature, and
pressure to define the rate of reactions. In cases where it is
desirable to react two or more raw materials of different phases
(e.g., solid and liquid; liquid and gas; solid, liquid and gas),
one of the limiting factors in controlling the rate of reaction
involves the contact time of the reactants. In conventional
reactors, contact time for the reactants is often controlled by
mixing, which provides contact with two or more reactants involved
in a chemical reaction. A reactor assembly that comprises an
external high shear mixer makes possible decreased mass transfer
limitations and thereby allows the reaction to more closely
approach kinetic limitations. When reaction rates are accelerated,
residence times may be decreased, thereby increasing obtainable
throughput. Alternatively, where the current yield is acceptable,
decreasing the required residence time allows for the use of lower
temperatures and/or pressures than conventional processes.
Alternatively or additionally, yield of product may be increased
via the high shear system and process. In some cases, it may be
possible to reduce the reactor size while maintaining the same
product yield due to the use of a high shear mixer.
System for Production of Starch
[0016] The high shear starch production system will now be
described in relation to FIG. 1, which is a process flow diagram
showing an embodiment of a high shear system 1 for the production
of starch from corn kernels. The basic components of the system
include external high shear mixing device (HSD) 40, vessel or
reactor 10, and pump 5. As shown in FIG. 1, the high shear device
is located external to vessel/reactor 10. Each of these components
is described in more detail below. Line 20 is connected to pump 5
for introducing a liquid stream containing an aqueous corn slurry.
Line 13 connects pump 5 to HSD 40, and line 18 connects HSD 40 to
vessel 10. Line 22 is connected to line 13 for introducing sulfur
dioxide gas, or a solution containing dissolved sulfur dioxide.
Line 17 is connected to vessel 10 for removal of vent gas.
Additional components or process steps may be incorporated between
vessel 10 and HSD 40, or ahead of pump 5 or HSD 40, if desired.
[0017] A grinder 4 is configured for cracking the corn kernels and
loosening the hulls to provide a grist of the desired particle
size. The grinder 4 may be a conventional dry-type or a wet-type
grinder, depending on whether a pre-soaking tank 2 is attached. In
FIG. 1 the arrow from pre-soaking tank 2 is drawn with a dashed
line to indicate that the use of tank 2 is optional in some
applications. A conventional germ and hull separator 6 is
configured for separating out the lighter hulls of the corn and for
delivering the denser corn grist to vessel 10. Line 8 joins
separator 6 to vessel 10. Outlet line 16 from vessel 10 is
configured for attaching to a screening assembly 24, which is
followed by a starch-gluten separator 26. At least one inlet line
15 is coupled to vessel 10 for introducing water, bisulfite
solution, or other materials.
[0018] High Shear Mixing Device. Referring still to FIG. 1,
external high shear mixing device (HSD) 40, also sometimes referred
to as a high shear mixer, is positioned between pump 5 and reactor
10 and is configured for receiving an inlet stream via line 13.
Alternatively, system 1 may be configured with more than one inlet
line (not shown). For instance, HSD 40 may be configured for
separately receiving corn grist slurry and sulfur dioxide via
separate inlet lines (not shown). Although only one high shear
device is shown in FIG. 1, it should be understood that some
embodiments of the system may have two or more high shear mixing
devices arranged either in series or parallel flow. HSD 40 is a
mechanical device that utilizes one or more generators comprising a
rotor/stator combination, each of which has a fixed gap between the
stator and rotor. HSD 40 is configured to produce a dispersion
containing submicron--(i.e., less than one micron in diameter) and
micron-sized bubbles containing SO.sub.2 gas dispersed in an
aqueous medium flowing through the mixing device. In some
embodiments, HSD 40 is also configured in such a way that it is
capable of producing a dispersion containing submicron--(i.e., less
than one micron in diameter) and micron-sized corn particles
dispersed in an aqueous medium flowing through the mixer. The high
shear mixer comprises an enclosure or housing so that the pressure
and temperature of the mixture may be controlled.
[0019] High shear mixing devices are generally divided into three
general classes, based upon their ability to mix fluids. Mixing is
the process of reducing the size of particles or inhomogeneous
species within the fluid. One metric for the degree or thoroughness
of mixing is the energy density per unit volume that the mixing
device generates to disrupt the fluid particles. The classes are
distinguished based on delivered energy densities. Three classes of
industrial mixers having sufficient energy density to consistently
produce mixtures or dispersions with particle or bubble sizes in
the range of submicron to 50 microns include homogenization valve
systems, colloid mills and high speed mixers. In the first class of
high energy devices, referred to as homogenization valve systems,
fluid to be processed is pumped under very high pressure through a
narrow-gap valve into a lower pressure environment. The pressure
gradients across the valve and the resulting turbulence and
cavitation act to break-up any particles in the fluid. These valve
systems are most commonly used in milk homogenization and can yield
average particle sizes in the 0-1 micron range.
[0020] At the opposite end of the energy density spectrum is the
third class of devices referred to as low energy devices. These
systems usually have paddles or fluid rotors that turn at high
speed in a reservoir of fluid to be processed, which in many of the
more common applications is a food product. These low energy
systems are customarily used when average particle sizes of greater
than 20 microns are acceptable in the processed fluid.
[0021] Between the low energy devices and homogenization valve
systems, in terms of the mixing energy density delivered to the
fluid, are colloid mills, which are classified as intermediate
energy devices. A typical colloid mill configuration includes a
conical or disk rotor that is separated from a complementary,
liquid-cooled stator by a closely-controlled rotor-stator gap,
which is commonly between 0.0254 and 10.16 mm (0.001-0.40 inch).
Rotors are usually driven by an electric motor through a direct
drive or belt mechanism. As the rotor rotates at high rates, it
pumps fluid between the outer surface of the rotor and the inner
surface of the stator, and shear forces generated in the gap
process the fluid. Many colloid mills with proper adjustment
achieve average particle sizes of 0.1-25 microns in the processed
fluid. These capabilities render colloid mills appropriate for a
variety of applications including colloid and oil/water-based
emulsion processing such as that required for cosmetics,
mayonnaise, or silicone/silver amalgam formation, to roofing-tar
mixing.
[0022] An approximation of energy input into the fluid (kW/L/min)
can be estimated by measuring the motor energy (kW) and fluid
output (L/min). Tip speed is the circumferential distance traveled
by the tip of the rotor per unit of time. Tip speed is thus a
function of the rotor diameter and the rotational frequency. Tip
speed (in meters per minute, for example) may be calculated by
multiplying the circumferential distance transcribed by the rotor
tip, 2.pi.R, where R is the radius of the rotor (in meters, for
example) times the frequency of revolution (in revolutions per
minute). A colloid mill, for example, may have a tip speed in
excess of 22.9 m/sec (4500 ft/min) and may exceed 40 m/sec (7900
ft/min). For the purposes of this disclosure, the term "high shear"
refers to mechanical rotor stator devices (e.g., colloid mills or
rotor/stator mixers) that are capable of tip speeds in excess of
5.1 m/sec. (1000 ft/min) and require an external mechanically
driven power device to drive energy into the stream of materials to
be reacted. For example, in HSD 40, a tip speed in excess of 22.9
m/sec (4500 ft/min) is achievable, and may exceed 40 m/sec (7900
ft/min). In some embodiments, HSD 40 is capable of delivering at
least 300 L/h with a power consumption of about 1.5 kW at a nominal
tip speed of at least 22.9 m/sec (4500 ft/min).
[0023] HSD 40 combines high tip speeds with a very small shear gap
to produce significant shear on the material being processed. The
amount of shear will be dependant on the viscosity of the fluid.
Accordingly, a local region of elevated pressure and temperature is
created at the tip of the rotor during operation of the high shear
device. In some cases the locally elevated pressure is about 1034.2
MPa (150,000 psi). In some cases the locally elevated temperature
is about 500.degree. C. In some cases these local pressure and
temperature elevations may persist for nano or pico seconds. In
some embodiments, the energy expenditure of the high shear mixer is
greater than 1000 W/m.sup.3. In embodiments, the energy expenditure
of HSD 40 is in the range of from about 3000 W/m.sup.3 to about
7500 W/m.sup.3. The shear rate is the tip speed divided by the
shear gap width (minimal clearance between the rotor and stator).
The shear rate generated in HSD 40 may be greater than 20,000
s.sup.-1. In some embodiments the shear rate is at least 1,600,000
s.sup.-1. In embodiments, the shear rate generated by HSD 40 is in
the range of from 20,000 s.sup.-1 to 100,000 s.sup.-1. For example,
in one application the rotor tip speed is about 40 m/sec (7900
ft/min) and the shear gap width is 0.0254 mm (0.001 inch),
producing a shear rate of 1,600,000 s.sup.-1. In another
application the rotor tip speed is about 22.9 msec (4500 ft/min)
and the shear gap width is 0.0254 mm (0.001 inch), producing a
shear rate of about 902,000 s.sup.-1.
[0024] In some embodiments, HSD 40 comprises a colloid mill.
Suitable colloidal mills are manufactured by IKA.RTM. Works, Inc.
Wilmington, N.C. and APV North America, Inc. Wilmington, Mass. for
example. In some instances, HSD 40 comprises the DISPAX
REACTOR.RTM. of IKA.RTM. Works, Inc. Several models are available
having various inlet/outlet connections, horsepower, nominal tip
speeds, output rpm, and nominal flow rate. Selection of a
particular device will depend on specific throughput requirements
for the intended application, and on the desired bubble or particle
size in the outlet dispersion from the high shear mixer. In some
embodiments, selection of the appropriate mixing tools (generators)
within HSD 40 allows for corn flour or grit size reduction and
increase in particle surface area.
[0025] The high shear device comprises at least one revolving
element that creates the mechanical force applied to the reactants.
The high shear device comprises at least one stator and at least
one rotor separated by a clearance. For example, the rotors may be
conical or disk shaped and may be separated from a
complementary-shaped stator; both the rotor and stator may comprise
a plurality of circumferentially-spaced teeth. In some embodiments,
the stator(s) are adjustable to obtain the desired gap between the
rotor and the stator of each generator (rotor/stator set). Grooves
in the rotor and/or stator may change directions in alternate
stages for increased turbulence. Each generator may be driven by
any suitable drive system configured for providing the necessary
rotation.
[0026] In some embodiments, the minimum clearance between the
stator and the rotor is in the range of from about 0.0254 mm to
about 3.175 mm (about 0.001 inch to about 0.125 inch). In certain
embodiments, the minimum clearance between the stator and rotor is
about 1.524 mm (0.060 inch). In certain configurations, the minimum
clearance between the rotor and stator is at least 1.778 mm (0.07
inch). The shear rate produced by the high shear mixer may vary
with longitudinal position along the flow pathway. In some
embodiments, the rotor is set to rotate at a speed commensurate
with the diameter of the rotor and the desired tip speed. In some
embodiments, the colloidal mill has a fixed clearance between the
stator and rotor. Alternatively, the colloid mill has adjustable
clearance.
[0027] In some embodiments, HSD 40 comprises a single stage
dispersing chamber (i.e., a single rotor/stator combination, a
single generator). In some embodiments, high shear device 40 is a
multiple stage inline colloid mill and comprises a plurality of
generators. In certain embodiments, HSD 40 comprises at least two
generators. In other embodiments, high shear device 40 comprises at
least 3 high shear generators. In some embodiments, high shear
device 40 is a multistage mixer whereby the shear rate (which
varies proportionately with tip speed and inversely with
rotor/stator gap) varies with longitudinal position along the flow
pathway, as further described herein below.
[0028] In some embodiments, each stage of the external high shear
device has interchangeable mixing tools, offering flexibility. For
example, the DR 2000/4 DISPAX REACTOR.RTM. of IKA.RTM. Works, Inc.
Wilmington, N.C. and APV North America, Inc. Wilmington, Mass.,
comprises a three stage dispersing module. This module may comprise
up to three rotor/stator combinations (generators), with choice of
fine, medium, coarse, and super-fine for each stage. This allows
for creation of dispersions having a narrow distribution of the
desired particle size. In some embodiments, each of the stages is
operated with super-fine generator. In some embodiments, at least
one of the generator sets has a rotor/stator minimum clearance of
greater than about 5.08 mm (0.20 inch). In some embodiments, at
least one of the generator sets has a minimum rotor/stator
clearance of greater than about 1.778 mm (0.07 inch). In some
embodiments the rotors are 60 mm and the are stators 64 mm in
diameter, providing a clearance of about 4 mm.
[0029] Referring now to FIG. 2, there is presented a longitudinal
cross-section of a suitable high shear device 200. High shear
device 200 is a dispersing device comprising three stages or
rotor-stator combinations, 220, 230, and 240. Three rotor/stator
sets or generators 220, 230, and 240 are aligned in series along
drive input 250. The first generator 220 comprises rotor 222 and
stator 227. The second generator 230 comprises rotor 223, and
stator 228; the third generator 240 comprises rotor 224 and stator
229. For each generator the rotor is rotatably driven by input 250
and rotates, as indicated by arrow 265, about axis 260. Stator 227
is fixedly coupled to high shear device wall 255. Each generator
has a shear gap which is the distance between the rotor and the
stator. First generator 220, comprises a first shear gap 225;
second generator 230 comprises a second shear gap 235; and third
generator 240 comprises a third shear gap 245. In some embodiments,
shear gaps 225, 235, 245 are between about 0.025 mm and 10.0 mm
wide. In some embodiments, the process comprises utilization of a
high shear device 200 wherein the gaps 225, 235, 245 are between
about 0.5 mm and about 2.5 mm. In certain instances the gap is
maintained at about 1.5 mm. Alternatively, the gaps 225, 235, 245
are different for generators 220, 230, 240. In certain instances,
the gap 225 for the first generator 220 is greater than about the
gap 235 for the second generator 230, which is in turn greater than
about the gap 245 for the third generator. As mentioned above, the
generators of each stage may be interchangeable, offering
flexibility.
[0030] Generators 220, 230, and 240 may comprise a coarse, medium,
fine, and super-fine characterization. Rotors 222, 223, and 224 and
stators 227, 228, and 229 may be toothed designs. Each generator
may comprise two or more sets of rotor-stator teeth. Rotors 222,
223, and 224 may comprise a number of rotor teeth circumferentially
spaced about the circumference of each rotor. Stators 227, 228, and
229 may comprise a complementary number of stator teeth
circumferentially spaced about the circumference of each stator. In
some embodiments, the inner diameter of the rotor is about 11.8 cm.
In embodiments, the outer diameter of the stator is about 15.4 cm.
In certain embodiments, each of three stages is operated with a
super-fine generator, comprising a shear gap of between about 0.025
mm and about 3 mm. For applications in which solid particles line
corn flour or grit are to be sent through high shear device 200,
shear gap width may be selected for reduction in particle size and
increase in particle surface area. In some embodiments, the
disperser is configured so that the shear rate will increase
stepwise longitudinally along the direction of the flow. The
IKA.RTM. model DR 2000/4, for example, comprises a belt drive, 4M
generator, PTFE sealing ring, inlet flange 25.4 mm (1 inch)
sanitary clamp, outlet flange 19 mm (3/4 inch) sanitary clamp, 2 HP
power, output speed of 7900 rpm, flow capacity (water)
approximately 300-700 L/h (depending on generator), a tip speed of
from 9.4-41 m/sec (1850 ft/min to 8070 ft/min).
[0031] Reactor/Vessel. Vessel or reactor 10 is any type of vessel
in which an aqueous slurry of grist can be prepared and
subsequently removed to pump 5. For instance, vessel 10 may be a
continuous or semi-continuous stirred tank reactor, or it may
comprise one or more batch reactors arranged in series or in
parallel. One or more line 15 may be connected to vessel 10 for
introducing the water, bisulfite solution, or other material.
Vessel 10 may include one or more of the following items: stirring
system, heating and/or cooling capabilities, pressure measurement
instrumentation, temperature measurement instrumentation, one or
more injection points, and level regulator (not shown), as are
known in the art of reaction vessel design. For example, a stirring
system may include a motor driven mixer. A heating and/or cooling
apparatus may comprise, for example, a heat exchanger. Line 16 is
connected to vessel 10 for removal of the starch product.
[0032] Heat Transfer Devices. In addition to the above-mentioned
heating/cooling capabilities of vessel 10, other external or
internal heat transfer devices for heating or cooling a process
stream are also contemplated in variations of the embodiments
illustrated in FIG. 1. Some suitable locations for one or more such
heat transfer devices are between pump 5 and HSD 40, between HSD 40
and vessel 10, and between vessel 10 and pump 5 when system 1 is
operated in multi-pass mode. Some non-limiting examples of suitable
heat transfer devices are shell, tube, plate, and coil heat
exchangers, as are known in the art.
[0033] Pump. Pump 5 is configured for either continuous or
semi-continuous operation, and may be any suitable pumping device
that is capable of providing greater than 203 kPa (2 atm) pressure,
preferably greater than 3 atm pressure, to allow controlled flow
through HSD 40 and system 1. For example, a Roper Type 1 gear pump,
Roper Pump Company (Commerce Georgia) Dayton Pressure Booster Pump
Model 2P372E, Dayton Electric Co (Niles, Ill.) is one suitable
pump. Preferably, all contact parts of the pump comprise stainless
steel. If corrosive substances are to be pumped it may be desirable
to provide gold plated contact surfaces. In some embodiments of the
system, pump 5 is capable of pressures greater than about 2027 kPa
(20 atm). In addition to pump 5, one or more additional, high
pressure pump (not shown) may be included in the system illustrated
in FIG. 1. For example, a booster pump, which may be similar to
pump 5, may be included between HSD 40 and vessel 10 for boosting
the pressure into vessel 10. As another example, a supplemental
feed pump, which may be similar to pump 5, may be included in line
15 for introducing additional water, or bisulfite solution into
vessel 10. Line 21 connects vessel 10 to line 20 for introducing
the initial corn slurry into HSD 40 via pump 5 and line 13, or for
multi-pass operation, as further described herein below. As still
another example, a compressor type pump may be positioned between
line 17 and HSD 40 for recycling SO.sub.2 gas from vessel 10 to an
inlet of the high shear device.
Production of Starch from Corn Grist
[0034] With reference to FIG. 1, when the system 1 is used to
produce starch, the desired quantity of ground corn kernels
(referred to as grist) and water are first combined in vessel 10,
which may be a batch reactor or any other suitable vessel, to form
a slurry. The grist may be prepared by conventional wet or dry
grinding techniques in grinder 4 to coarsely grind the kernels to
break the germ loose from other components. Grist is in the form of
a meal or flour, depending on how coarsely it is ground. For
example, the mean particle size of the grist may be about 2
millimeters in some applications, when it is initially introduced
to vessel 10. For some applications, especially when a more highly
refined starch product is desired (i.e., containing minimal
residual protein), it is preferred to grind the corn kernels in
such a manner that the hulls are fractured without damaging the
germ (e.g., using approximately 3-4 millimeter roller clearances).
For some applications, the corn kernels are pre-soaked in water (in
tank 2) prior to wet grinding in grinder 4. A relatively brief
soaking (e.g., about 1-6 hours) in water is employed to soften the
kernels, allowing the germ to become hydrated and pliable enough to
resist fracturing and breaking during coarse grinding.
[0035] Using known wet or dry milling techniques, the ground corn
is separated to provide a grist containing coarse or fine particles
that are substantially free of the hull and germ. The
starch-containing grist is fed via line 8 from separator 6 into
vessel 10 where it is mixed with water to form a slurry. In some
applications the slurry contains about 10-40 wt % grist. The
temperature of the slurry in vessel 10 may be controlled using any
suitable known method. For example, the reaction stream may be
maintained at a specified reaction temperature, using cooling coils
in vessel 10 to maintain reaction temperature. The use of
additional external heating and/or cooling heat transfer devices is
also contemplated in some applications of the process. For some
applications, reactor 10 may primarily serve to cool/hold the
initial corn grist slurry, as much or a substantial portion of the
starch extraction from the corn grist occurs in HSD 40 and during
transit through system 1, as further described below.
[0036] In lieu of a traditional steeping stage, the slurry in
reactor 10 flows through lines 21 and 20 to pump 5 and line 13,
which delivers the slurry to high shear HSD 40. Potential
advantages of eliminating the traditional steeping stage of the
process are the reduced opportunity for microbial growth and
avoidance of the loss or the need to recover any starch that is
released into the steep water. Pump 5 is operated to pump the
liquid stream (i.e., corn slurry) from reactor/vessel 10, via lines
21 and 20, and to build pressure and feed HSD 40, providing a
controlled flow through line 13 and high shear mixer (HSD) 40, and
throughout high shear system 1. In some embodiments, pump 5
increases the pressure of the liquid stream to greater than 203 kPa
(2 atm), preferably greater than about 304 kPa (3 atm). In some
applications, pressures greater than about 2027 kPa (20 atm) may be
used to accelerate reactions, with the limiting factor being the
pressure limitations of the selected pump 5 and HSD 40. In many
embodiments, it is preferred to keep the pressure high enough
throughout system 1 to keep the SO.sub.2 in solution. For the
purposes of this disclosure, the terms "superficial pressure" and
"superficial temperature" refer to the apparent, bulk, or measured
pressure or temperature, respectively, in a vessel, conduit or
other apparatus of the system. The actual temperatures and/or
pressures at which the components make contact and interact in the
microenvironment of a transient cavity produced by the hydrodynamic
forces of the high shear mixer may be quite different, as further
discussed elsewhere herein.
[0037] Gaseous SO.sub.2 is injected via line 22 into feed line 13
as the aqueous corn slurry flows into HSD 40, where the components
are subjected to high shear mixing. Additional water may be
introduced into line 13, or, in some embodiments, additional water
may be introduced independently into HSD 40. Alternatively, or
additionally, in some circumstances it may be desirable to
initially dissolve a portion of the desired amount of sulfur
dioxide in the corn slurry in vessel 10 prior to withdrawing the
slurry via line 21 and transferring it to HSD 40 via lines 20 and
13, so that the aqueous slurry contains a corresponding amount of
bisulfite ions when it initially enters HSD 40. In this case,
additional SO.sub.2 gas may be introduced into the
bisulfite-containing stream via line 22 if necessary for a
particular application.
[0038] After pumping, the corn flour slurry stream 13 mixes with
sulfur dioxide gas 22 in HSD 40, which serves to create fine
mixture, emulsion or dispersion of the corn flour, sulfur dioxide
gas, and aqueous bisulfite solution. The high shear mixing of the
slurry components exposes particle surfaces for more intensive
hydration and to facilitate chemical reactions with the dissolved
SO.sub.2 and with the emulsified gaseous SO.sub.2, to enhance the
release of starch and gluten from the fiber matrix in the
particles.
[0039] As used herein, the term "dispersion" refers to a liquefied
mixture that contains two distinguishable substances (or phases)
that will not readily mix and dissolve together. A dispersion
comprises a continuous phase (or matrix), which holds therein
discontinuous globules, droplets, bubbles, and/or particles of the
other phase or substance. The term dispersion may thus refer to
foams comprising gas bubbles suspended in a liquid continuous
phase, emulsions in which droplets of a first liquid are dispersed
throughout a continuous phase comprising a second liquid with which
the first liquid is immiscible, and continuous liquid phases
throughout which solid particles are distributed. The term
"dispersion" encompasses continuous liquid phases throughout which
gas bubbles are distributed, continuous liquid phases throughout
which solid particles (e.g., corn flour particles) are distributed,
continuous phases of a first liquid throughout which droplets of a
second liquid that is substantially insoluble in the continuous
phase are distributed, and liquid phases throughout which any one
or a combination of solid particles, immiscible liquid globules or
droplets, and gas bubbles are distributed. Hence, a dispersion can
exist as a homogeneous mixture in some cases (e.g., liquid/liquid
phase), or as a heterogeneous mixture (e.g., gas/liquid,
solid/liquid, or gas/solid/liquid), depending on the nature of the
materials selected for combination.
[0040] In the instant process, the SO.sub.2 gas is highly dispersed
such that nanobubbles and microbubbles of SO.sub.2 are formed which
enhance dissolution of the SO.sub.2 into the aqueous medium. In
some applications, the amount of dissolved SO.sub.2 (sulfite) in
the dispersion is no more than about 1-2 wt %, or a specific pH
(e.g., 2.5).
[0041] In HSD 40, the corn slurry and SO.sub.2 are highly dispersed
such that nano- and micro-bubbles containing SO.sub.2, together
with finely dispersed particles of corn, are formed for superior
dissolution into solution and/or enhancement of intimate mixing.
For example, disperser IKA.RTM. model DR 2000/4, a high shear,
three stage dispersing device configured with three rotors in
combination with stators, aligned in series, is used to create a
dispersion of dispersible SO.sub.2 in aqueous medium comprising the
corn particles and dissolved SO.sub.2. The rotor/stator sets may be
configured as illustrated in FIG. 2, for example. For some
applications, the direction of rotation of the generators may be
opposite that shown by arrow 265 (e.g., clockwise or
counterclockwise about axis of rotation 260). The combined
reactants entering the high shear mixer via line 13 proceed to a
first stage rotor/stator combination having circumferentially
spaced first stage shear openings. In some applications, the
direction of flow of the reactant stream entering inlet 205
corresponds to the axis of rotation 260. The coarse dispersion
exiting the first stage enters the second rotor/stator stage,
having second stage shear openings. The reduced particle-size
dispersion emerging from the second stage enters the third stage
rotor/stator combination having third stage shear openings.
[0042] In some embodiments, the shear rate increases stepwise
longitudinally along the direction of the flow. For example, in
some embodiments, the shear rate in the first rotor/stator stage is
greater than the shear rate in subsequent stage(s). In other
embodiments, the shear rate is substantially constant along the
direction of the flow, with the stage or stages being the same. If
the high shear mixer includes a PTFE seal, for example, the seal
may be cooled using any suitable technique that is known in the
art. For example, the slurry stream flowing in line 13 may be used
to cool the seal and in so doing be preheated as desired prior to
entering the high shear mixer.
[0043] The rotor of HSD 40 is set to rotate at a speed commensurate
with the diameter of the rotor and the desired tip speed. As
described above, the high shear mixer (e.g., colloid mill) has
either a fixed clearance between the stator and rotor or has
adjustable clearance. HSD 40 serves to intimately mix SO.sub.2 gas
and corn particles with the liquid phase (e.g., water and dissolved
SO.sub.2). In some embodiments of the process, the transport
resistance of the slurry components is reduced by operation of the
high shear mixer such that the velocity of the reaction is
increased by greater than a factor of 5. In some embodiments, the
velocity of the reaction is increased by at least a factor of 10.
In some embodiments, the velocity is increased by a factor in the
range of about 10 to about 100 fold. In some embodiments, HSD 40
delivers at least 300 L/h with a power consumption of 1.5 kW at a
nominal tip speed of at least 22.9 m/sec (4500 ft/min), and which
may exceed 40 m/sec (7900 ft/min). Although measurement of
instantaneous temperature and pressure at the tip of a rotating
shear unit or revolving element in HSD 40 is difficult, it is
estimated that the localized temperature seen by the intimately
mixed reactants is in excess of 500.degree. C. and at pressures in
excess of 5000 kPa (500 kg/cm.sup.2) under cavitation conditions.
The high shear mixing results in dispersion of the corn particles
and the SO.sub.2 bubbles as micron or submicron-sized bubbles
(i.e., mean diameter less than one micron). In some embodiments,
the resultant dispersion has an average bubble size less than about
1.5 .mu.m. In some embodiments, the mean bubble size is less than
one micron in diameter. Accordingly, the dispersion exiting HSD 40
via line 18 comprises micron and/or submicron-sized gas-filled
bubbles. In some embodiments, their mean size is in the range of
about 0.4 .mu.m to about 1.5 .mu.m. In some embodiments, the mean
size is less than about 400 nm, in the range of about 200 nm to
about 400 nm, or is about 100 nm in some cases. In some
embodiments, the sizes of the particles or bubbles in the dispersed
phase are less than 1000 nanometers (i.e., submicron or <1
micron in diameter). It is known in emulsion chemistry that
sub-micron particles or bubbles dispersed in a liquid undergo
movement primarily through Brownian motion effects. Without being
limited to a specific theory to explain certain features or
benefits of the present methods, it is proposed that sub-micron gas
particles created by the high shear mixer have greater mobility
thereby facilitating and accelerating at least the hydration
reaction through greater transport of water and chemical
components. In many embodiments, the dispersion is able to remain
dispersed at atmospheric pressure for at least 15 minutes.
[0044] Once dispersed, the resulting dispersion exits high shear
mixer 40 via line 18. Extraction and solubilization of starch will
occur whenever suitable time, temperature and pressure conditions
exist, facilitated by the presence of the dissolved and emulsified
SO.sub.2. In this sense, the extraction and solubilization of
starch may occur at any point in the flow diagram of FIG. 1 where
temperature and pressure conditions are suitable. In some
embodiments, a significant portion of the hydration, extraction and
dissolution of starch takes place in the high shear mixer. A
discrete reaction vessel (reactor 10) is usually desirable,
however, to allow for increased residence time, agitation and
heating and/or cooling. Accordingly, the output from HSD 40 feeds
into vessel 10, as illustrated in FIG. 1, wherein starch extraction
and solubilization occurs or continues to take place. If desired,
the dispersion may be further processed prior to entering vessel
10. For example, further mixing in one or more successive high
shear mixing devices, similar to HSD 40 with the same or different
generator configurations, may be performed, before the process
stream enters reactor/vessel 10.
[0045] After the highly dispersed mixture is fed into reactor 10
via line 18, starch release into the slurry may continue to take
place. The dispersion may be allowed to stand in vessel 10 for a
selected time to permit at least some settling of the solids and
release of suspended SO.sub.2 gas bubbles. The temperature of the
dispersion in reactor 10 may be appropriately controlled. Vent gas
may exit vessel 10 via line 17. Vent gas stream 17 may comprise
SO.sub.2 and other volatile compounds, for example. If desired, the
vent gas stream 17 may be further treated to absorb the SO.sub.2 or
it may be recovered for recycle to the process using techniques
that are known. In some instances, it may be desirable to use a
compressor type pump to recycle vent gases in line 17 back into HSD
40.
[0046] For some applications of a high shear process, a superficial
pressure of less than about 600 kPa and a superficial temperature
less than about 200.degree. C. is maintained in at least the high
shear mixing device and reactor of system 1. For the purposes of
this disclosure, the terms "superficial pressure" and "superficial
temperature" refer to the apparent or measured pressure or
temperature, respectively, in a vessel, conduit or apparatus of the
starch production system. The actual temperatures and/or pressures
at which the reactants make contact and react in the
microenvironment of a transient cavity produced by the hydrodynamic
forces of the high shear mixer may be quite different.
[0047] In various applications, starch production is carried out as
a multi-pass, continuous flow process or as a single-pass or batch
process. Accordingly, the starch product may be produced either
continuously, semi-continuously or batch wise, as desired. The
product stream comprising extracted, solubilized starch and fully
or partially extracted corn particles, and extracted gluten protein
exits vessel 10 by line 16. In some embodiments, a plurality of
reactor product lines 16 are used to remove the product. In
instances in which a single pass or "once through" process is
desired, the use of only a single high shear mixer or a group of
multiple high shear mixers in parallel arrangement may be preferred
in order to avoid subjecting the extracted starch and protein
molecules to excessive shear forces.
[0048] Multiple Pass Operation. Referring still to FIG. 1, the
system is configured for either single pass or multi-pass
operation, wherein, after the initial preparation of the corn
slurry in vessel 10 and commencement of the process, the output
from line 16 of vessel 10 goes directly to recovery of the starch
product or to further processing, as described below. In some
embodiments it may be desirable to pass the contents of vessel 10,
or a portion thereof containing fresh and/or incompletely extracted
corn particles, through HSD 40 during a second pass. In this case,
the dispersion and the initially solubilized starch may be returned
via lines 21 and 20, pump 5, and line 13, to HSD 40, for further
dispersion and reaction. Additional SO.sub.2 may be injected via
line 22 into line 13, or it may be added directly into the high
shear mixer, if needed. Additional water may be injected at line
13, if needed. In some multi-pass embodiments, it is preferred to
provide for extraction of protein and oil fractions between passes
through the high shear mixer(s). For example, some embodiments may
utilize a series of high shear mixing devices with progressively
lower shear gaps, and provide for intervening separation of the
germ protein and oil, as needed. In such embodiments, the output
from line 16 is screened and separated to remove protein (e.g.,
gluten) and oil from the particulates, which can then be returned
as a slurry to HSD 40.
[0049] Alternatively, in some embodiments, two or more high shear
devices like HSD 40, or differently configured devices, are aligned
in series, and are used to further enhance the reaction. Their
operation may be in either batch or continuous mode. In some
instances in which a single pass or "once through" process is
desired, the use of multiple high shear devices in series may also
be advantageous. For instance, in some applications, where shorter
starch molecules are desired, the product may be recycled via lines
21 and 20, to pump 5, and through high shear mixer 40, before
returning via line 18 to vessel 10.
[0050] After the desired processing, the resulting starch-gluten
intermediate product is removed from system 1 via line 16 to screen
assembly 24 and from there to starch-gluten separator 26. Suitable
screening and separator apparatus are known in the art. In some
embodiments, a plurality of outlet lines similar to line 16 are
used to remove the starch-gluten intermediate. In screen assembly
24 the resulting dispersion, containing starch, gluten and fiber,
flows over screens that catch fiber but allow starch and gluten to
pass through. The resulting starch-gluten mixture (mill starch), is
transferred to one or more starch separator 26, which may be a
centrifuge or other suitable device, wherein the starch fraction is
separated. Because gluten has a lower density than starch, the
gluten can be centrifuged out of the starch fraction. If desired,
further washing may be done to remove residual protein. The
recovered starch may be dried, further processed to obtain
derivative products, or it may be used directly as a feedstock to a
selected downstream process, such as manufacturing of drilling
mud.
[0051] The application of enhanced mixing of the reactants by HSD
40 potentially causes greater extraction and solubilization of
starch in some embodiments of the process. In some embodiments, the
enhanced mixing potentiates an increase in throughput of the
process stream. In some embodiments, the high shear mixing device
is incorporated into an established starch extraction process,
thereby causing an increase in production (i.e., greater
throughput). Without wishing to be limited to a particular theory,
it is believed that the level or degree of high shear mixing is
sufficient to increase rates of mass transfer and may also produce
localized non-ideal conditions that enable reactions to occur that
might not otherwise be expected to occur based on Gibbs free energy
predictions. Localized non ideal conditions are believed to occur
within the high shear device resulting in increased temperatures
and pressures with the most significant increase believed to be in
localized pressures. The increase in pressures and temperatures
within the high shear device are instantaneous and localized and
quickly revert back to bulk or average system conditions once
exiting the high shear device. In some cases, the high shear mixing
device induces cavitation of sufficient intensity to dissociate one
or more of the reactants into free radicals, which may intensify a
chemical reaction or allow a reaction to take place at less
stringent conditions than might otherwise be required. Cavitation
may also increase rates of transport processes by producing local
turbulence and liquid micro-circulation (acoustic streaming). An
overview of the application of cavitation phenomenon in
chemical/physical processing applications is provided by Gogate et
al., "Cavitation: A technology on the horizon," Current Science 91
(No. 1): 35-46 (2006). The high shear mixing device of certain
embodiments of the present system and methods is operated under
what is believed to be cavitation conditions effective to
dissociate some reactants into free radicals which then.
[0052] Potential benefits of various embodiments of the present
systems and methods for the production of starch include, but are
not limited to, faster cycle times, increased throughput, higher
extraction and solubilization rates, reduced operating costs and/or
reduced capital expense due to the possibility of designing smaller
reactors and/or operating the process at lower temperature and/or
pressure. In some embodiments, use of the disclosed process
comprising reactant mixing via external high shear mixing device 40
allows greater yield of starch and/or an increase in throughput of
the reactants. In some embodiments, the method comprises
incorporating external high shear mixer into an established starch
production plant, thereby making possible an increase in production
(greater throughput) compared to a similar process operated without
an external high shear mixer. In some embodiments, a disclosed
process or system makes possible the design of a smaller and/or
less capital intensive process than previously possible without the
incorporation of an external high shear mixer.
[0053] While preferred embodiments of the invention have been shown
and described, modifications thereof can be made by one skilled in
the art without departing from the spirit and teachings of the
invention. The embodiments described herein are exemplary only, and
are not intended to be limiting. Many variations and modifications
of the invention disclosed herein are possible and are within the
scope of the invention. For example, although extraction of starch
from corn (Zea mays) is discussed in particular, it should be
understood that the same or similar processes are applicable to
other starting materials as well, including but not limited to,
various cereal and root materials including milo, sorgham, wheat,
rice, arrowroot, beet, potato and tapioca. "Corn" is considered to
be representative of such other suitable source materials for
production of starch.
[0054] Where numerical ranges or limitations are expressly stated,
such express ranges or limitations should be understood to include
iterative ranges or limitations of like magnitude falling within
the expressly stated ranges or limitations (e.g., from about 1 to
about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11,
0.12, 0.13, and so forth). Use of the term "optionally" with
respect to any element of a claim is intended to mean that the
subject element is required, or alternatively, is not required.
Both alternatives are intended to be within the scope of the claim.
Use of broader terms such as comprises, includes, having, etc.
should be understood to provide support for narrower terms such as
consisting of, consisting essentially of, comprised substantially
of, and the like.
[0055] Accordingly, it should be understood that the scope of
protection is not limited by the description set out above but is
only limited by the claims which follow, that scope including all
equivalents of the subject matter of the claims. Each and every
original claim is incorporated into the specification as an
embodiment of the invention. Thus, the claims are a further
description and are an addition to the preferred embodiments of the
invention. The disclosures of all patents, patent applications, and
publications cited herein are hereby incorporated by reference, to
the extent they provide exemplary, procedural or other details
supplementary to those set forth herein.
* * * * *