A system for fermentation based protein production

Abstract

The present disclosure discloses a system (100) for fermentation based protein production. The system (100) includes a fermenter (1) to convert gaseous raw material into biomass broth. Further, the system includes a concentrator (2) fluidly connected to the fermenter (1). The concentrator separates water content from a concentrated cell slurry of the biomass broth received from the fermenter (1). The separated water content from the biomass broth in the concentrator (2) is channelized back into the fermenter (1). A dryer (4) is fluidly connected to the concentrator, to remove liquid content from the concentrated cell slurry to form a dried biomass, where exhaust gases from the fermenter is adaptably processed to dry the concentrated cell slurry in the dryer. Furthermore, the system includes a finishing unit (5) which is connected downstream of the dryer (4), adapted to receive and process the dried biomass into packaged protein product.

Description

A SYSTEM FOR FERMENTATION BASED PROTEIN PRODUCTION  TECHNICAL FIELD [1] Present disclosure relates, in general, to the field of production engineering. Particularly, but not exclusively, the present disclosure relates to a system for production of fermentation-based protein. BACKGROUND OF DISCLOSURE  [2] Generally, protein is produced through sugar fermentation or plant-based processes. Typically, sugar fermentation processes involve use of sugars in the form of monosaccharides, disaccharides, starch, or carbohydrates as raw material and gases are used to support catalytic reactions to convert the raw material into biomass and products. As raw materials are organic in nature it contributes a higher percentage to the overall cost of fermentation. On the other hand, plant-based protein production is quite intensive in terms of land, water, and time requirement. For example, in order to generate 1 kg of protein, soyabean based process requires around 2200 L water.  [3] Alternatively, gases can be used as raw material for biomass growth and protein production, which is commonly termed as gas fermentation. The gas fermentation utilizes cheaper raw material and reduces greenhouse gases. However, during gas fermentation processes, the utilization of gas substrates is not complete, and the unutilized gases are either flared or recycled back into the system. While flaring is a waste of economically important energy, recycling the exhaust gases back to the fermenter requires additional separation and purification step which increases the overall production cost. Additionally, the protein production includes filtering of the fermented biomass and removing excess water from the biomass. Such residual water leads to pollution and the treatment of such residual water is not a straightforward process and requires in-depth study and process modification depending upon the industry where it is applied. Lastly, protein production includes drying of the filtered biomass, which is generally carried out by combusting fuels. Such fuels increase the production cost and combustion of the fuels leads to environmental pollution, which is undesired. [4] The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the known arts. [5] The drawbacks / difficulties / disadvantages / limitations of the conventional techniques explained in the background section are just for exemplary purpose and the disclosure would never limit its scope only such limitations. A person skilled in the art would understand that this disclosure and below mentioned description may also solve other problems or overcome the other drawbacks / disadvantages of the conventional arts which are not explicitly captured above.  SUMMARY OF THE DISCLOSURE [6] One or more shortcomings of the conventional arts are overcome, and additional advantages are provided through a system, as disclosed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure. [7] In a non-limiting embodiment of the present disclosure, a system for fermentation based protein production is disclosed. The system includes a fermenter to convert gaseous raw material into biomass broth. Further, the system includes a concentrator which is fluidly connected to the fermenter. The concentrator separates water content from a microbial cell slurry of the biomass broth received from the fermenter. The separated water content from the biomass broth in the concentrator is channelized back into the fermenter. Additionally, the system includes a dryer that is fluidly connected to the concentrator. The dryer removes liquid content from the concentrated cell slurry to form a dried biomass, where exhaust gases from the fermenter are adaptably utilized to dry the concentrated cell slurry in the dryer. Furthermore, the system includes a finishing unit which is connected downstream of the dryer. The finishing unit is adapted to receive and process the dried biomass into packaged protein product. [8] In an embodiment, the system includes a boiler which is fluidly connected to the dryer to supply steam into the dryer. The boiler receives exhaust gases from the fermenter to generate steam.  [9] In an embodiment, the dryer is fluidly connected to the fermenter to receive exhaust gases and dry the concentrated cell slurry. 

[10] In an embodiment, the system includes a purging unit which is fluidly coupled to the concentrator. The purging unit selectively channelizes separated water content from the concentrator to the fermenter. 

[11] In an embodiment, the system includes a control module which is operatively coupled to the fermenter, the boiler, the dryer, the concentrator, the purging unit, the desalination unit, and the finishing unit. The control module is configured to operate the system. 

[12] In an embodiment, the control module includes a controller, one or more sensors and one or more valves, to operate the system. 

[13] In an embodiment, the system includes a desalination unit which may be fluidly connectable between the purging unit and the fermenter. The desalination unit desalinates the water content being channelized by the purging unit. 

[14] In an embodiment, the gaseous raw material is selected from a group comprising methane, natural gas, biogas, air, oxygen, carbon di-oxide, hydrogen, syngas, or carbon monoxide and any combinations thereof. 

[15] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. 

[16] BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS  

[17] The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:  

[18] Fig. 1 illustrates a block diagram of a system for fermentation based protein production, in accordance with an embodiment of the present disclosure. 

[19] Fig. 2 illustrates a block diagram of a system for fermentation based protein production, in accordance with another embodiment of the present disclosure. 

[20] Fig. 3 illustrates a block diagram of a system for fermentation based protein production, in accordance with another embodiment of the present disclosure. 

[21] Fig. 4 illustrates a block diagram of a system for fermentation based protein production, in accordance with another embodiment of the present disclosure. 

[22] The figure depicts embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein. 

[23] DETAILED DESCRIPTION 

[24] The foregoing section has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the description of the disclosure. It should also be realized by those skilled in the art that such equivalent methods do not depart from the scope of the disclosure. The novel features which are believed to be characteristic of the disclosure, as to method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

[25] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.

[26] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.

[27] The terms “comprises”, “comprising,” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a method that comprises a list of acts does not include only those acts but may include other acts not expressly listed or inherent to such method. In other words, one or more acts in a method proceeded by “comprises… a” does not, without more constraints, preclude the existence of other acts or additional acts in the method.

[28] Henceforth, the present disclosure is explained with the help of figures illustrating a system for fermentation based protein production. However, such exemplary embodiments should not be construed as limitations of the present disclosure. A person skilled in the art can envisage various such embodiments without deviating from the scope of the present disclosure. 

[29] Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. The following paragraphs describe the present disclosure with reference to Figs. 1 to4. 

[30] Fig. 1 illustrates a block diagram of a system (100) for fermentation based protein production. The system (100) includes a fermenter (1) which may be adapted to carry out fermentation. In an embodiment, the inputs to the system (100) may be including but not limited to microorganisms, gaseous substrate and growth media. For example, the inputs may be selected from microorganism, gaseous substrate / gaseous raw material and growth media described in patent application, having publication number WO2020095281A1. Further, the fermenter (1) is adapted to carry out fermentation in presence of feed water. In some embodiments, the fermenter (1) may be employed for microbial cultivation using gaseous substrate. For example, the gaseous substrate / gaseous raw material may be selected from including but not limited a group comprising methane, natural gas, biogas, air, oxygen, carbon di-oxide, hydrogen, carbon monoxide, syngas and any combinations thereof. Further, in an example, the microorganism may be including but not limited to C1 carbon utilizing organisms. That is, the fermenter (1) may be adapted to ferment or carry out the microbial cultivation using / in presence of gaseous substrate such but not limited to methane, biogas, natural gas, oxygen in the form of air or enriched oxygen, carbon di-oxide, hydrogen, carbon monoxide, syngas, or any combination thereof. Further, the fermenter (1) may receive feed water along with raw materials for carrying out the fermentation process. The fermenter (1) may generate biomass by utilizing a portion of the gases introduced into the fermenter (1) which may be in the form of a broth. In an embodiment, the fermenter (1) may be including but not limited to an airlift type fermenter, a bubble column fermenter, a stirred tank reactor fermenter, a plug flow reactor and the like.

[31] Further, the system (100) may include a concentrator (2) which may be fluidly connected to the fermenter (1). The biomass broth from the fermenter (1) may be channelized into the concentrator (2). The concentrator (2) may be configured to separate water content from a microbial cell slurry of the biomass broth received from the fermenter (1). In an embodiment, the concentrator (2) may be including but not limited to a centrifuge type concentrator, a filtration type concentrator, a evaporator type concentrator, a crystallization type concentrator and the like. The water that may be separated from the biomass broth in the concentrator (2) that may be channelized back into the fermenter (1). In an embodiment, the fermenter (1) and the concentrator (2) may be fluidly connected with each other through at least one of duct, pipes, conduits and the like. The configuration of the system (100) that enables channelizing of water from the concentrator (2) to the fermenter (1) for further processing mitigates wastage of water and thereby eliminates requirement of large amounts of feed water that may be required for fermentation process. Additionally, by recycling the water from the concentrator (2), the water is not dispensed out of the industry thereby, mitigating water pollution.

[32] Additionally, the system (100) may include a purging unit (7) which may be fluidly coupled to the concentrator (2). The purging unit (7) may selectively channelize the separated water content from the concentrator (2) to the fermenter (1). In an embodiment, the purging unit (7) may be adapted to purge the water content from the concentrator (2). Upon purging the water content from the fermenter (1), the purging unit (7) may at least one of channelize the water content back to the fermenter (1) or dispense the water content out of the system (100), or both based on operational requirement. That is, the purging unit (7) may channelize the water content back to the fermenter (1) when there may be requirement of water content to be added back to the feed water and may dispense the water content out of the system (100) when there may not be any requirement of recycled feed water, or may carry out both operations simultaneously to regulate the amount of water content being channelized back to fermenter (1). The recycled water may be fed or mixed with the feed water such that water from both the feed line and the concentrator (2) are mixed and channelized into the fermenter (1). In an embodiment, the purging unit (7) may include at least one valve which may be adapted to selectively direct flow of fluid being channelized in the purging unit (7). Additionally, at least one valve may also be configured to regulate flow rate, and cutoff flow of fluid within the purging unit (7). Furthermore, the purging unit (7) may also include at least one flow meter detect flow rate and enable an operator or a controller to operate the purging unit (7) based on operating conditions of the system (100). Furthermore, both lines [fluid lines carrying water from the feed source and the concentrator (2)] may be equipped with valves (not shown in the Figs) to monitor and control water flow from each line according to requirement. The channelizing of the water from the concentrator (2) to the fermenter (1) may fulfill up to 95% of the fermenter (1) water requirement and reduce addition of fresh water for carrying out the fermentation process. This may in turn mitigate wastage of water and thereby eliminate the requirement of large amounts of feed water that may be required for fermentation process. Additionally, by recycling the water from the concentrator (2), the water is not dispensed out of the system (100) thereby, mitigating water pollution.

[33] Furthermore, in an embodiment as seen in Fig. 2, the system (100) may include a desalination unit (8) which may be fluidly connectable between the purging unit (7) and the fermenter (1). The fluid being channelized from the concentrator (2) to the fermenter (1) may flow through the desalination unit (8). The desalination unit (8) may be adapted to desalinate the water content being channelized by the purging unit (7) before the water content reaches the fermenter (1). The desalination unit (8) may be required to process the water content such that the water content being fed back into the fermenter (1) may be as per the required standards. For example, the desalination unit (8) may be one of but not limited to a membrane based filtration unit, an ion exchange unit, a distillation unit and the like.

[34] Further, referring back to Fig. 1, the system (100) may include a dryer (4) which may be fluidly connected to the concentrator (2). The concentrated cell slurry [having the water content removed] from the concentrator (2) may be channelized into the dryer (4). In an embodiment, the dryer (4) may be including but not limited to a spray dryer, a drum dryer, a tray dryer, a freeze dryer, a fluidized bed dryer, an air dryer, a radiation based dryer and the like. The dryer (4) may be adapted to receive the concentrated cell slurry and remove remaining liquid content to meet required specifications of dried biomass. In an embodiment, the dryer (4) may be fluidly connected directly to the fermenter (1). The unused gases and / or released gases [hereafter referred to as exhaust gases] from the fermenter (1) during fermentation process may be channelized from the fermenter (1) to the dryer (4). The exhaust gases from the fermenter (1) may be employed for combustion in the dryer (4) to dry the concentrated cell slurry. In an embodiment, the fermenter (1) and the dryer (4) may be fluidly connected to each other by means of including but not limited to hoses, pipes, conduits, ducts and the like. Typical fate of exhaust gases from the fermenter (1) is either release into atmosphere or flaring. Venting out may contribute to air pollution while flaring is a waste of energy and economic value. Capturing such exhaust gases for the combustion process in the dryer (4) results in reducing the external energy requirement for drying, thereby decreasing the operational costs and environmental pollution. In an embodiment, the dryer (4) may refer to a drying unit which may comprise a direct fired dryer or an indirect fired dryer. Further, the direct fired dryer consists of a dryer fitted with necessary accessories to heat the process air along with firing of fermenter (1) exhaust gases for drying. In case of indirect fired dryer, the unit may include a heat exchanger coupled with dryer whereby process air is heated via heat exchanger through firing of fermenter (1) exhaust gases separately and the heated process air is transferred to the dryer (4). The exhaust gases from the fermenter (1) during fermentation process may be channelized from the fermenter (1) to the dryer (4). The exhaust gases from the fermenter (1) may be employed for operating the dryer (4) as the exhaust gases from the fermenter (1) may directly be transferred to dryer (4) for flaring which generates heat for drying. That is, the exhaust gases from the fermenter (1) may be channelized directly into the dryer (4) for generating heat and removing excess liquid content from the cell slurry to form a dried biomass. Hence, capturing the exhaust gases for operating the dryer (4) directly results in reducing the requirement of extra energy and additional heating units, thereby decreasing the operational costs during production of dried biomass.

[35] In an embodiment, referring to Fig. 3, the system (100) may include a boiler (3) which may be fluidly connected between the fermenter (1) and the dryer (4). The boiler (3) may be a steam boiler (3) and may be fluidly connected to the dryer (4) to supply steam into the dryer (4). That is, the boiler (3) may be configured to generate steam that may be utilized by the dryer (4) to dry the concentrated cell slurry. The steam from the boiler (3) may be utilized to operate the dryer (4) for removing liquid content from concentrated cell slurry to form the dried biomass. The boiler (3) due to fluid connection with the fermenter (1) may be adapted to receive exhaust gases from the fermenter (1) and generate steam. The exhaust gases from the fermenter (1) may be employed for combustion in the boiler (3) to produce steam. Typical fate of exhaust gases from the fermenter (1) is either release into atmosphere or flaring. Venting out may contribute to air pollution while flaring is a waste of energy and economic value and capturing such exhaust gases for the combustion process in the boiler (3) results in reducing the external energy requirement in the boiler (3), thereby decreasing the operational costs and environmental pollution.

[36] Further, as seen in Fig. 3, the system (100) employing the boiler (3) may not include the desalination unit (8), however, this should not be considered as a limitation as, the system (100) employing the boiler (3) may include the desalination unit (8) as well fluidly connectable between the purging unit (7) and the fermenter (1) [as seen in Fig. 4]. Such desalination unit (8) may be adapted to desalinate the water content being channelized by the purging unit (7).

[37] Furthermore, as seen in Figs. 1-4, the system (100) may include a finishing unit (5) which may be fluidly connected downstream of the dryer (4). The finishing unit (5) may receive the dried biomass from the dryer which may be further processed to obtain protein. The obtained protein may be in the form of an unpackaged protein product. Additionally, the finishing unit (5) may be utilized for packaging and other necessary operations for producing and obtaining the packaged protein product [hereafter termed as final product]. In an embodiment, the finishing unit (5) may include suitable means for packaging the obtained protein.

[38] Additionally, in an embodiment, the system (100) may include control module (6) which may be operatively coupled to the fermenter (1), the boiler (3), the dryer (4), the concentrator (2), the purging unit (7), the desalination unit (8) and the finishing unit (5) for operating each component of the system (100).The control module (6) may include but not limited to controllers, one or more sensors, detectors one or more valves, and the like which aid in operating the system (100). In an embodiment, the control module (6) may be configured to regulate flow and combustion in the boiler (3) and / or dryer (4).

[39] In an embodiment, the conduit channelizing exhaust gas line from the fermenter (1) may be connected to the control module (6) which may also be connected to a natural gas feed line and the dryer (4) through the boiler (3). The detectors of the control module (6) may be employed for estimating exhaust gas composition and energy content in the exhaust gases of the fermenter (1) which may determine the required flow rate of fresh natural gas feed. The fresh natural gas here refers to the additional fresh gas which may be required for operating the dryer (4) or the boiler (3). In an embodiment, the system (100) may be fluidly connected to a fresh gas source to receive the fresh gases. Additionally, the system (100) may include additional elements such as IoT devices [for example, hardware components such as sensors, actuators, gadgets, appliances, or machines, that are programmed for specific applications / functions in the system (100) and can transmit data over the internet or other networks] for automatic sampling and detection and opening and closing of valves and adjustment of gas flow rates based on requirement in the system (100). In an alternate embodiment, the system (100) may be manually monitored and controlled by an operator based on determination of parameters.

[40] In an embodiment, the system (100) may include one or more valves which may be connected between the components of the system (100) for controlling fluid or material flow between each of the components of the system (100). Such valves may be automatically operated by the controller of the control module (6) or may be manually operated by the operator based on requirement. Additionally, the one or more sensors may be associated with different components of the system (100) such that operating parameters may be continuously measured by such one or more sensors. The one or more sensors may transmit signals to the controller and the controller upon receiving such signals from the one or more sensors may operate the components of the system (100).

[41] In an embodiment, a memory unit may be communicatively coupled to the controller or the control module (6). For example, the memory unit may be in electronic communication with the controller. The memory unit may store instructions executable by the controller. The controller may comprise at least one data processor for executing program components for executing user or system (100) generated requests. The instructions, which, on execution by the controller, may cause the controller to determine the current operating condition of the system (100) based on the signals received from the operator or the one or more sensors. Additionally, the system (100) may include I / O interface which may be coupled with the controller through which an input signal or / and an output signal is communicated. For example, the I / O interface may allow the controller to communicate with one or more nodes / devices either directly or through other devices. In an embodiment, the controller may be implemented in a variety of computing systems, such as a laptop computer, a desktop computer, a Personal Computer (PC), a notebook, a smartphone, a tablet, a server, a network server, a cloud-based server, and the like. 

[42] In another embodiment, the system (100) may include a network interface which may allow the controller to interact with one or more networks either directly or via any other network. For example, the controller may utilize the network interface to interact with a server via a communication network. 

[43] Additionally, the controller may communicatively connected with one or more input / output (I / O) devices (not shown) via the I / O interface. The I / O interface may employ communication protocols / methods such as, without limitation, audio, analog, digital, monoaural, RCA, stereo, IEEE (Institute of Electrical and Electronics Engineers) -1394, serial bus, universal serial bus (USB), infrared, PS / 2, BNC, coaxial, component, composite, digital visual interface (DVI), high-definition multimedia interface (HDMI), Radio Frequency (RF) antennas, S-Video, VGA, IEEE 802.n / b / g / n / x, Bluetooth, cellular (e.g., code-division multiple access (CDMA), high-speed packet access (HSPA+), global system for mobile communications (GSM), long-term evolution (LTE), WiMAX, or the like), etc. 

[44] Using the I / O interface, the controller may communicate with one or more I / O devices. For example, the input device may be an antenna, keyboard, mouse, joystick, (infrared) remote control, camera, card reader, fax machine, dongle, biometric reader, microphone, touch screen, touchpad, trackball, stylus, scanner, storage device, transceiver, video device / source, and the like. The output device may be a printer, fax machine, video display (e.g., cathode ray tube (CRT), liquid crystal display (LCD), light-emitting diode (LED), plasma, Plasma display panel (PDP), Organic light-emitting diode display (OLED) or the like), audio speaker, and the like. 

[45] The controller may communicatively connected with a communication network via a network interface. The network interface may communicate with the communication network. The network interface may employ connection protocols including, without limitation, direct connect, Ethernet (e.g., twisted pair 10 / 100 / 1000 Base T), transmission control protocol / internet protocol (TCP / IP), token ring, IEEE 802.11a / b / g / n / x, and the like. The communication network may include, without limitation, a direct interconnection, local area network (LAN), wide area network (WAN), wireless network (e.g., using Wireless Application Protocol), the Internet, and the like. The network interface (304) may employ connection protocols include, but not limited to, direct connect, Ethernet (e.g., twisted pair 10 / 100 / 1000 Base T), transmission control protocol / internet protocol (TCP / IP), token ring, IEEE 802.11a / b / g / n / x, and the like. 

[46] Further, the communication network may include but not limited to, a direct interconnection, an e-commerce network, a peer to peer (P2P) network, local area network (LAN), wide area network (WAN), wireless network (e.g., using Wireless Application Protocol), the Internet, Wi-Fi, and such. The network may either be a dedicated network or a shared network, which represents an association of the several types of networks that use a variety of protocols, for example, Hypertext Transfer Protocol (HTTP), Transmission Control Protocol / Internet Protocol (TCP / IP), Wireless Application Protocol (WAP), etc., to communicate with each other. Further, the network may include a variety of network devices, including routers, bridges, servers, computing devices, storage devices, and the like. Further, the controller may receive data items (e.g., the one or more control parameters and the one or more input parameters) over the communication network. 

[47] In some embodiments, the controller may communicatively connected with a memory (e.g., RAM, ROM, and the like) via a storage interface (not shown). The storage interface (not shown) may connect to memory including, without limitation, memory drives, removable disc drives, and the like, employing connection protocols such as serial advanced technology attachment (SATA), Integrated Drive Electronics (IDE), IEEE-1394, Universal Serial Bus (USB), fiber channel, Small Computer Systems Interface (SCSI), cloud based servers, cloud based storage units and the like. The memory devices may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, Redundant Array of Independent Discs (RAID), solid-state memory devices, solid-state drives, and the like. 

[48] The memory may store a collection of program or database components, including, without limitation, user interface (not shown), an operating system (not shown), web browser (not shown), and the like. In some embodiments, the controller may store operator / user / application data, such as, the data, variables, records, and the like, as described in this disclosure. Such databases may be implemented as fault-tolerant, relational, scalable, secure databases such as Oracle ® or Sybase®. The memory may be communicatively coupled to the controller. The memory stores instructions, executable by the controller, which, on execution, may cause the controller to determine the current storage conditions based on the one or more obtained control parameters and the one or more received input parameters in the system (100). 

[49] Furthermore, one or more computer-readable storage media may be utilized in implementing embodiments consistent with the present disclosure. A computer-readable storage medium refers to any type of physical memory on which information or data readable by the controller may be stored. Thus, a computer-readable storage medium may store instructions for execution by the controller, including instructions for causing the controller to perform steps or stages consistent with the embodiments described herein. The term “computer-readable medium” should be understood to include tangible items and exclude carrier waves and transient signals, i.e., be non-transitory. Examples include Random Access Memory (RAM), Read-Only Memory (ROM), volatile memory, non-volatile memory, hard drives, Compact Disc Read-Only Memory (CD ROMs), Digital Video Disc (DVDs), flash drives, disks, and any other known physical storage media.

[50] In an embodiment, the system (100) facilitates maximum gas utilization which is introduced into the fermenter (1) for fermentation process. In addition, the system (100) enables recycling of water in the fermentation process.

[51] In an embodiment, upto 95% of the feed water which may be used for fermentation is recycled back to the fermenter (1) from the concentrator (2) after cell separation. Any remaining water may be treated or may evaporate during drying process.

[52] In an operational embodiment, gaseous raw materials along with water may be introduced into the fermenter (1). The fermenter (1) may then carry out the microbial cultivation. During the microbial cultivation, the fermenter (1) may convert the gaseous raw material into biomass which may be in the form of a broth. Upon generation of the biomass broth, the operator or the controller may detect such generation, to operate the control module (6) for channelizing the biomass broth into the concentrator (2). The concentrator (2) may receive the biomass broth and separate the water content from a microbial cells slurry of the biomass broth received from the fermenter (1). The operator or the controller may operate the control module (6) to channelize the separated water content to the purging unit (7) which may then channelize the recycled water back to the fermenter (1) by mixing the recycled water with the feed water. Upon removal of the separated water from the concentrator (2), the operator or the controller may operate the control module (6) for channelizing the concentrated cell slurry [having the water content removed] from the concentrator (2) into the dryer (4). Simultaneously, the operator or the controller may operate the control module (6) to channelize the exhaust gases from the fermenter (1) into the dryer (4) for operating the dryer (4). In the dryer (4), the concentrated cell slurry may be subjected to drying operation where, liquid content is removed to meet the required specification of the dried biomass. After generating the dried biomass, the operator or the controller may operate the control module (6) to channelize the dried biomass to the finishing unit (5) where the dried biomass is processed further to form the final product. This configuration of the system (100) enables efficient protein production with optimal usage of water, exhaust gases, thereby reducing operational materials, costs and environmental pollution.

[53] Examples: 

[54] The conventional fermenters for producing biomass have been compared with the system (100) of the present disclosure. The examples were carried out considering the operational period to be between 1 to 300 days. The different inputs employed may be selected from microorganism, gaseous substrate and growth media described in patent application, having publication number WO2020095281A1. More particularly, C1 carbon utilizing organisms, gaseous substrate (methane, biogas, natural gas, carbon di-oxide, hydrogen, air, oxygen, carbon monoxide, syngas, and any combination thereof) and optimized growth media were employed in the examples. 

[55] In an example, when the fermentation was carried out according to conventional production systems, 25-1600L of water per day was introduced into the fermenter. Upon fermentation process, the exhaust gases from the fermenter were required to be flared in a flaring unit. Further, the contents from the fermenter were transferred to the concentrator, where the water content separated was purged out of the concentrator either to a treatment plant. Further, the contents from the concentrator were transferred to the dryer, where 20-1200 MJ of energy per day was consumed by the dryer through gases which were fed to the dryer from a gas reservoir. After drying, the contents from the dryer were transferred to the finishing unit, where, approximately 1-50 Kgs of final product yield was obtained per day. 

[56] . In one example, when the fermentation was carried out in accordance with the system (100) of the present disclosure, the system received fresh water in a range of 300-9000L and recycled water from the concentrator in the range of 600-9000L of water per day which was introduced into the fermenter. Upon fermentation process, the exhaust gases from the fermenter were sent to the dryer / boiler that amounts to 1000-12000MJ of energy per day which was consumed by the dryer / boiler to form the dried biomass without any external energy requirements. After drying, the contents from the dryer were transferred to the finishing unit, where, approximately 50-500Kgs of final product was obtained per day. 

[57] In another example, when the fermentation was carried out in accordance with the system (100) of the present disclosure, the system received fresh water in a range of 550-10000L and recycled water from the concentrator in the range of 200-6500L of water per day which was introduced into the fermenter. Upon fermentation process, the exhaust gases from the fermenter were sent to the dryer / boiler that amounts to 400-7000MJ of energy per day and additional fresh gases that amounts to 400-7000MJ which was consumed by the dryer / boiler to form the dried biomass. After drying, the contents from the dryer were transferred to the finishing unit, where, approximately 40-450Kgs of final product was obtained per day. 

[58] In another example, when the fermentation was carried out in accordance with the system (100) of the present disclosure, the system received fresh water in a range of 200-6500L and recycled water from the concentrator in the range of 650-11000L of water per day which was introduced into the fermenter. Upon fermentation process, the exhaust gases from the fermenter were sent to the dryer / boiler that amounts to 1000-12000MJ of energy per day which was consumed by the dryer / boiler to form the dried biomass. After drying, the contents from the dryer were transferred to the finishing unit, where, approximately 50-500Kgs of final product yield was obtained per day. 

[59] In another example, when the fermentation was carried out in accordance with the system (100) of the present disclosure, the system received fresh water in a range of 300-6000L and recycled water from the concentrator in the range of 650-11000L of water per day which was introduced into the fermenter. Upon fermentation process, the exhaust gases from the fermenter were sent to the dryer / boiler that amounts to 200-3000MJ of energy per day and additional fresh gases that amounts to 700-10000MJ which was consumed by the dryer / boiler to form the dried biomass. After drying, the contents from the dryer were transferred to the finishing unit, where, approximately 55-550Kgs of final product yield was obtained per day. 

[60] In another example, when the fermentation was carried out in accordance with the system (100) of the present disclosure, the system received fresh water in a range of 3000-450000L and recycled water from the concentrator in the range of 6000-1200000L of water per day which was introduced into the fermenter. Upon fermentation process, the exhaust gases from the fermenter were sent to the dryer / boiler that amounts to 10000-1200000MJ of energy per day which was consumed by the dryer / boiler to form the dried biomass. After drying, the contents from the dryer were transferred to the finishing unit, where, approximately 500-50000Kgs of final product yield was obtained per day. 

[61] The above examples clearly indicate that the system (100) of the present disclosure is capable of producing high protein yields with additional advantages of requiring less amount of fresh water which is to be fed into the fermenter due to recycling of the water content from the concentrator. Additionally, system (100) of the present disclosure is capable of producing high protein yields with low or negligible amount of fresh combustible gases for operating the boiler / dryer, when compared to the conventional systems.  

[62] It is to be understood that a person of ordinary skill in the art may develop a system (100) of similar configuration without deviating from the scope of the present disclosure. Such modifications and variations may be made without departing from the scope of the present invention. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents. 

[63] Equivalents:

[64] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for the sake of clarity.

[65] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and / or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general, such construction is intended in a sense that one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general, such construction is intended in a sense that one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[66] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[67] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims.

[68] Referral Numerals: 

[69] Reference Number

[70] Description

[71] 100

[72] System

[73] 1

[74] Fermenter

[75] 2

[76] Concentrator

[77] 3

[78] Boiler

[79] 4

[80] Dryer

[81] 5

[82] Finishing unit

[83] 6

[84] Control module

[85] 7

[86] Purging unit

[87] 8

[88] Desalination unit

[89]

[90] We claim: 

[91] A system (100) for fermentation based protein production, comprising:%3. a fermenter (1) to convert gaseous raw material into biomass broth and release of exhaust gases;%3. a concentrator (2) fluidly connected to the fermenter (1), to separate water content from a microbial cell slurry of the biomass broth received from the fermenter (1), wherein separated water content from the biomass broth in the concentrator (2) is channelized back into the fermenter (1);%3. a dryer (4) fluidly connected to the concentrator (2), to remove liquid content from the concentrated cell slurry to form a dried biomass, wherein the exhaust gases from the fermenter (1) are adaptably utilized to dry the concentrated cell slurry in the dryer (4); and%3. a finishing unit (5) connected downstream of the dryer (4), adapted to receive and process the dried biomass into packaged protein product. 

[92] The system (100) as claimed in claim 1 comprises a boiler (3) fluidly connected to the dryer (4) to supply steam into the dryer (4), wherein the boiler (3) receives exhaust gases from the fermenter (1) to generate steam. 

[93] The system (100) as claimed in claim 1, wherein the dryer (4) is fluidly connected to the fermenter (1) to receive exhaust gases to dry the concentrated cell slurry. 

[94] The system (100) as claimed in claim 1 comprises a purging unit (7) fluidly coupled to the concentrator (2), wherein the purging unit (7) selectively channelizes separated water content from the concentrator (2) to the fermenter (1). 

[95] The system (100) as claimed in claim 1 comprises a control module (6) operatively coupled to the fermenter (1), the boiler (3),the dryer (4), the concentrator (2), the purging unit (7), the desalination unit (8) and the finishing unit (5), wherein the control module (6) is configured to operate the system (100). 

[96] The system (100) as claimed in claim 5, wherein the control module (6) comprises a controller, one or more sensors and one or more valves, to operate the system (100).  

[97] The system (100) as claimed in claim 1 comprises a desalination unit (8) which is fluidly connectable between the purging unit (7) and the fermenter (1), wherein the desalination unit (8) desalinates the water content being channelized by the purging unit (7). 

[98] The system (100) as claimed in claim 1, wherein the gaseous raw material is selected from a group comprising methane, natural gas, biogas, air, oxygen, carbon di-oxide, hydrogen, syngas, or carbon monoxide and any combinations thereof.

[99]

[100] “A SYSTEM FOR FERMENTATION BASED PROTEIN PRODUCTION”

[101] ABSTRACT

[102] The present disclosure discloses a system (100) for fermentation based protein production. The system (100) includes a fermenter (1) to convert gaseous raw material into biomass broth. Further, the system includes a concentrator (2) fluidly connected to the fermenter (1). The concentrator separates water content from a concentrated cell slurry of the biomass broth received from the fermenter (1). The separated water content from the biomass broth in the concentrator (2) is channelized back into the fermenter (1). A dryer (4) is fluidly connected to the concentrator, to remove liquid content from the concentrated cell slurry to form a dried biomass, where exhaust gases from the fermenter is adaptably processed to dry the concentrated cell slurry in the dryer. Furthermore, the system includes a finishing unit (5) which is connected downstream of the dryer (4), adapted to receive and process the dried biomass into packaged protein product. 

[103] Fig. 1 is the representative figure.

Claims

A system (100) for fermentation based protein production, comprising:a fermenter (1) to convert gaseous raw material into biomass broth and release of exhaust gases;a concentrator (2) fluidly connected to the fermenter (1), to separate water content from a microbial cell slurry of the biomass broth received from the fermenter (1), wherein separated water content from the biomass broth in the concentrator (2) is channelized back into the fermenter (1);a dryer (4) fluidly connected to the concentrator (2), to remove liquid content from the concentrated cell slurry to form a dried biomass, wherein the exhaust gases from the fermenter (1) are adaptably utilized to dry the concentrated cell slurry in the dryer (4); anda finishing unit (5) connected downstream of the dryer (4), adapted to receive and process the dried biomass into packaged protein product. 2- The system (100) as claimed in claim 1 comprises a boiler (3) fluidly connected to the dryer (4) to supply steam into the dryer (4), wherein the boiler (3) receives exhaust gases from the fermenter (1) to generate steam. 3- The system (100) as claimed in claim 1, wherein the dryer (4) is fluidly connected to the fermenter (1) to receive exhaust gases to dry the concentrated cell slurry. 4- The system (100) as claimed in claim 1 comprises a purging unit (7) fluidly coupled to the concentrator (2), wherein the purging unit (7) selectively channelizes separated water content from the concentrator (2) to the fermenter (1). 5- The system (100) as claimed in claim 1 comprises a control module (6) operatively coupled to the fermenter (1), the boiler (3),the dryer (4), the concentrator (2), the purging unit (7), the desalination unit (8) and the finishing unit (5), wherein the control module (6) is configured to operate the system (100). 6- The system (100) as claimed in claim 5, wherein the control module (6) comprises a controller, one or more sensors and one or more valves, to operate the system (100).  7- The system (100) as claimed in claim 1 comprises a desalination unit (8) which is fluidly connectable between the purging unit (7) and the fermenter (1), wherein the desalination unit (8) desalinates the water content being channelized by the purging unit (7). 8- The system (100) as claimed in claim 1, wherein the gaseous raw material is selected from a group comprising methane, natural gas, biogas, air, oxygen, carbon di-oxide, hydrogen, syngas, or carbon monoxide and any combinations thereof.  

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