Method to produce high protein residuals

A system for treating whole stillage comprising corn oil, the system comprising:

• a whole stillage reservoir;
• a separation system in fluid communication with the whole stillage reservoir and configured to separate the whole stillage into a wet cake portion and a thin stillage portion comprising the corn oil,
• wherein the separation system includes one or more of a screen;
• a centrifuge;
• and a dissolved air flotation (DAF) system;
• a primary filtration system in fluid communication with the separation system and configured to filter the thin stillage portion into a primary concentrate and a primary permeate, wherein the corn oil remains in the primary concentrate,
• wherein the primary filtration system includes a member selected from a group consisting of a microfiltration system or an ultrafiltration system,
• a fermenter fluidly coupled to the primary permeate obtained from the primary filtration system, wherein the primary permeate is configured for being recycled as backset to the fermenter;
• a corn oil recovery system fluidly coupled to receive the primary concentrate obtained from the primary filtration system;
• an evaporator fluidly coupled to receive the primary concentrate obtained from the primary filtration system and the corn oil recovery system,
• wherein:
• the corn oil recovery system is located and configured to receive (i) the primary concentrate;
• or (ii) partially dewatered primary concentrate from the evaporator,
• the corn oil recovery system is configured to collect corn oil from the primary concentrate or the partially dewatered primary concentrate, and
• the evaporator is located and configured to receive the primary concentrate and remove water from the primary concentrate, wherein the evaporator is located and configured to receive the primary concentrate either from:
• (i) the corn oil recovery system;
• or (ii) the primary filtration system;
• and
• a dryer fluidly coupled to the evaporator and configured to receive the wet cake obtained from the separation system, wherein the dryer is located and configured to receive the dewatered primary concentrate from the evaporator and the wet cake from the separation system, wherein the dewatered primary concentrate and the wet cake are combined in the dryer and dried together to produce the high protein animal feed.