Low residence time gas separator

Abstract

The systems and methods disclosed herein provide for efficient separation of gases from a fluid comprising a liquid. In particular, disclosed herein are gas separator systems and methods for bioreactor systems and operations that provide an efficient means of removing gaseous waste, unreacted gaseous substrate, and / or inert gases from fermentation broth of a biological fermentation of a carbon substrate using a microbial biocatalyst.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. nonprovisional patent application No. 17 / 661,523, filed April 29, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The embodiments described herein generally relate to systems for separating gases from liquids. Other embodiments described herein generally relate to methods for removing gases from liquids. Specifically, this document discloses gas separator systems and methods for use with bioreactors, providing an efficient means of separating gaseous waste from the effluent of a carbon substrate biofermentation process introduced into a liquid fermentation broth containing a microbial culture. Background Technology

[0004] Systems for removing gaseous or solid waste from liquids generated in industrial processes are well-known. Biological and chemical reactor systems require small bubbles for better mass transfer, and biological systems with smaller substrate bubbles have improved efficiency in producing useful products through biofermentation. However, smaller bubbles are difficult to rise in liquids and require extended time periods to detach from the liquid in known separator systems. Therefore, conventional and known systems require large separator volumes to allow gases (such as waste gases produced as byproducts in gaseous fermentation, inert gases, unused substrate gases, etc.) to rise to the surface of the reaction fluid for eventual removal from the system. Typical gases separated from the fermentation effluent of a gaseous fermentation bioreactor can include CO2, CO, and H2. The fermentation effluent also contains the system's microbial biocatalyst and liquid nutrient solution. For example, due to the size of the separator volume required to completely remove gases from the fermentation effluent of a gaseous fermentation bioreactor, the system's microbial biocatalyst remains in the fermentation broth for extended periods without the need for the biocatalyst gaseous substrate required for fermentation and sustaining microbial life. Consequently, the microbial biocatalyst may prematurely lose its activity and thus limit the efficiency of the overall fermentation reaction. Furthermore, the large separator volume increases the footprint and space required for the entire reactor and separator system, thereby increasing component and operating costs. These known system limitations restrict the overall biocatalyst activity and the production of useful products. Therefore, there remains a need for gas separators with reduced volume to maximize biofermentation reactions in bioreactors.

[0005] Additionally, if off-gas is not removed from the fermentation broth effluent from the gas fermentation bioreactor, off-gas such as inert gas and / or CO2 will be recycled with the fermentation broth to the bioreactor. The inert gas and / or CO2 dilutes the amount of new biocatalyst gas substrate that can be incorporated into the recycled fermentation broth; new biocatalyst gas substrate that is needed to be available for fermentation by the microbial biocatalyst. Furthermore, to maximize fermentation by the microbial biocatalyst, small, fine, or micro-sized substrate gas bubbles are produced by the reactor system, such as by increasing the system superficial gas velocity. Residual inert gas and / or CO2 that is not removed from the system and recycled in the fermentation broth can expand within the reactor, limiting the superficial gas velocity and limiting the production of small, fine, or micro-sized bubbles.

[0006] Accordingly, there is a need for systems and methods that efficiently remove small, fine, or micro-sized bubbles in biological and chemical reactor systems using a reduced volume gas separator. The gas separator systems and methods disclosed herein overcome the limitations of conventional reactor and separator systems. SUMMARY

[0007] The following presents a simplified summary of various embodiments described herein. This summary is not an extensive overview, and is not intended to identify key or critical elements or to delineate the scope of the claims. The following summary merely presents some concepts in a simplified form as an introductory prelude to the more detailed description provided below.

[0008] To overcome the limitations in the prior art described above, and to overcome other limitations that will be apparent to read and understand the present specification, the embodiments described herein are directed to systems and methods for efficiently separating gas from a liquid.

[0009] In one embodiment, the systems disclosed herein relate to separating gas from a liquid and can include a separator vessel, a fluid inlet engaged with the separator vessel, at least one gas outlet engaged with the separator vessel, at least one liquid outlet engaged with the separator vessel, a plurality of inclined plates positioned within the separator vessel, and a fluid distributor positioned within the separator vessel and engaged with the plurality of inclined plates. In some examples, the fluid distributor can further include a first end proximate the fluid inlet and a second end distal from the fluid inlet. The fluid distributor can be in physical contact with the fluid inlet. In other examples, the fluid distributor has a uniform width. In other examples, the first end of the fluid distributor can be wider than the second end. In another example, the fluid distributor can include a plurality of apertures positioned on at least two sides of the fluid distributor. The top, sides, and bottom of the fluid distributor can form a rectangular cross-section. In another example, a plurality of fluid directing internals are positioned within the fluid distributor. In another example, the fluid distributor can include an upper portion positioned above the top portion of the plurality of inclined plates and a lower portion positioned above the bottom portion of the plurality of inclined plates. In other examples, the separator vessel can be cylindrical and the cylindrical separator vessel can be oriented on a horizontal plane. In yet another example, the cylindrical separator vessel can be positioned above at least the bottom third portion of the reactor vessel. In some examples, the plurality of inclined plates can have a spacing between individual plates of about 25 mm to 200 mm. In another example, the plurality of inclined plates can be angled at about 45 degrees to about 80 degrees relative to a horizontal axis. In another example, the inclined plates have a bottom portion that engages a perforated plate.

[0010] In another aspect, the methods disclosed herein relate to separating a gas from a liquid and can include feeding a fluid comprising a liquid and a gas into an inlet of a separator vessel, delivering the fluid into a fluid distributor within the separator vessel, directing the fluid within the fluid distributor and uniformly washing a plurality of inclined plates positioned within the separator vessel along a length of the fluid distributor through orifices in the fluid distributor; causing the gas to rise against the plurality of inclined plates, discharging the liquid through at least one liquid outlet, and removing the gas through at least one gas outlet. In one example, the method includes washing the plurality of inclined plates with the fluid via orifices positioned on a side of the fluid distributor. In some examples, the fluid flow within the fluid distributor is directed via a fluid directing internal within the fluid distributor. In other examples, the method can further include pressurizing the separator vessel, and the separator vessel can be cylindrical. In another example, the cylindrical separator vessel can be positioned on a horizontal plane. In some examples, the fluid distributor can include a plurality of orifices positioned on a bottom portion of the fluid distributor. In one example, an upper portion of the fluid distributor can be positioned above a top portion of the plurality of inclined plates, and a lower portion of the fluid distributor can be positioned above a bottom portion of the plurality of inclined plates. In yet another example, the method can further include washing the plurality of inclined plates with a first volume of fluid via a plurality of orifices positioned on an upper portion of the fluid distributor, and washing the plurality of inclined plates with a second volume of fluid via a lower portion of the fluid distributor. In some examples, the first volume of fluid washing the plurality of inclined plates can comprise about 30% of a total liquid volume, and the second volume of fluid washing the plurality of inclined plates can comprise about 70% of the total liquid volume. In other examples, the method can include maintaining a constant cross-flow velocity and a constant bubble separation velocity across the plurality of inclined plates, and can include recycling the discharged liquid in a closed system.

[0011] In another aspect, the systems disclosed herein relate to bioreactor systems comprising a reaction vessel and a gas separation vessel. In certain examples, the reaction vessel can comprise a fluid comprising a liquid growth medium, off-gas, substrate gas, and a culture of at least one microorganism. In some examples, the substrate gas can comprise at least one Ci carbon source. In another example, the culture of at least one microorganism can anaerobically or aerobically ferment the substrate gas to produce at least one fermentation product and off-gas. The gas separation vessel is in fluid communication with the reaction vessel and is used to remove the substrate gas and off-gas from the fermentation broth. In other examples, the gas separator vessel is positioned above the bottom third portion of the reaction vessel. A fluid inlet of the gas separator vessel can be in fluid communication with the reaction vessel, and at least one gas outlet of the gas separator vessel can be in fluid communication with the reaction vessel. At least one liquid growth medium outlet can be in fluid engagement with the separator vessel. The gas separator vessel can also comprise a plurality of inclined plates positioned within the separator vessel, and a fluid distributor positioned within the separator vessel to engage the plurality of inclined plates. In other examples, the fluid distributor can comprise a fluid directing internal. In other examples, a pump can be configured to recirculate the liquid growth medium and the culture of at least one microorganism from the separator to the reaction vessel. In other examples, the system can be pressurized, and the system can be free of a throttle valve between the reaction vessel and the gas separator fluid inlet.

[0012] These features, and many others, are discussed in greater detail below. BRIEF DESCRIPTION OF DRAWINGS

[0013] A more complete understanding of the embodiments described herein, and the advantages thereof, can be acquired by referring to the following description in consideration with the accompanying drawings, in which like reference numbers indicate like features. Commonly known elements often useful or necessary in commercially feasible embodiments are typically not shown in the drawings so as to less obscure the observation of the various embodiments of the present disclosure.

[0014] Figure 1 A conventional bioreactor system having a conventional gas separator is schematically depicted.

[0015] Figure 2 A bioreactor system having a novel gas separator according to the systems and methods disclosed herein is schematically depicted.

[0016] Figure 3 A cross-sectional side view and associated liquid fluid flow pattern of an embodiment of a gas separator according to the systems and methods disclosed herein is shown.

[0017] Figure 4 An alternative cross-sectional view of a gas separator comprising a liquid fluid and gas circulation pattern is shown.

[0018] Figure 5 An alternative cross-sectional view of a gas separator including a liquid fluid circulation pattern is shown.

[0019] Figure 6 A cross-sectional side view and associated liquid fluid flow pattern of an embodiment of a gas separator according to the systems and methods disclosed herein is shown.

[0020] Figure 7 An alternative cross-sectional end view and associated liquid fluid flow pattern of an embodiment of a gas separator according to the systems and methods disclosed herein is shown.

[0021] Figure 8 An alternative cross-sectional top view of an embodiment of a gas separator according to the systems and methods disclosed herein is shown. DETAILED DESCRIPTION

[0022] In the following description of various embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration various embodiments in which aspects described herein can be practiced. It is to be understood that other embodiments can be utilized and that structural and functional modifications can be made without departing from the scope of the described embodiments. The embodiments described herein are capable of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. Rather, the phrases and terms used herein are to be given their broadest interpretation and meaning. The use of "including," "comprising," "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. The use of the terms "mounted," "connected," "engaged," "fluidly engaged," "coupled," "positioned," "configured," "oriented," and similar terms, is meant to include both direct and indirect mounting, connecting, engaging, fluidly engaging, coupling, positioning, and orienting.

[0023] Systems and methods as disclosed herein relate to the efficient separation of gas from a fluid containing liquid by using a gas separator that has a reduced volume compared to known conventional chemical and biological reactor systems. A gas separator is intended to include a unit for separating gas from a fluid containing liquid. In the example of a fermentation process, the fluid containing liquid can contain a mixture of gas, liquid, and a microbial culture. In other examples, without a microbial culture, the gas separator can be a gas-liquid separator. In particular, the systems and methods disclosed herein for a gas separator system and use in a biological reactor system provide an excellent means for removing small and / or fine gas bubbles from a fermentation broth containing a microbial culture. The fermentation broth containing a microbial culture is referred to as a fluid or liquid. Small, fine, and / or micro-sized gas bubbles have a smaller diameter compared to the gas bubbles produced by conventional reactor systems and distributors. Small, fine, and / or micro-sized gas bubbles do not rise through the liquid or fermentation broth fast enough to adequately disengage from the liquid or fermentation broth within a conventional separator in a reactor system. To allow for adequate disengagement of small, fine, and / or micro-sized gas bubbles, the residence time of the fermentation broth in the separator would need to be extended, which results in the microbial biocatalyst in the fermentation broth being starved of substrate for an extended period of time. The extended time of consumption of the microbial biocatalyst in the fermentation broth lacking proper feed gas (substrate) can result in an amount of microbial biomass that is no longer viable that no longer contributes to the production of product, resulting in inefficient fermentation of the desired reaction product. Therefore, due to the increased residence time and / or separator volume required by conventional separator systems, a new system is needed to rapidly remove small, fine, and / or micro gas bubbles. The gas separator disclosed herein reduces the required separator volume and recycles the fermentation broth back into the biological reactor vessel in a shorter amount of time while reducing small, fine, and / or micro gas bubbles, thereby promoting the growth and survival of the microbial biocatalyst. If small, fine, or micro gas bubbles are not adequately removed from the fermentation broth, the small, fine, and / or micro gas bubbles serve to dilute the entire mixture when the substrate gas is introduced into the recycled fluid. The mixing of the recycled gas bubbles and substrate gas reduces the conversion efficiency of the biocatalyst and limits the amount of useful product produced by the reaction. The general term separator is intended to include a gas separator, which includes a gas-liquid separator.

[0024] Systems and methods as disclosed herein employ an inclined plate within a gas separation vessel for efficient separation of small, fine, and / or microbubbles from a fluid comprising a liquid, such as a fermentation broth. Conventional systems using inclined plate settlers or lamella settlers are used for removal of fine particles in wastewater treatment that are different from the lamella settlers. However, the inclined plates disclosed herein are used for removal of gas from a fluid comprising a liquid, which is in direct contrast to conventional lamella settlers that are intended to remove solid particles from a liquid, primarily water. Thus, the configuration of the components within the gas separator or separator vessel and the location and configuration of the gas separator within the reactor system as a whole are significantly different from conventional systems. For example, conventional lamella settlers have an open top portion and are typically operated at atmospheric pressure, and the fluid or liquid typically enters the settler from the bottom or lower portion of the device. In contrast, the separators disclosed herein have the liquid and bubbles enter from the top portion of the separator vessel, and the liquid with removed bubbles exit from the bottom portion of the vessel. The separators disclosed herein can be a closed and pressurized system. In other examples, the separators disclosed herein can be non-pressurized. The gas separators disclosed herein can be used as part of a closed loop and pressurized bioreactor system for removal of small, fine, and / or microbubbles of substrate, inert gas, and / or other waste gases from the microbial fermentation broth effluent of a bioreactor. The gas at this stage of the system (post-bioreactor) is typically "spent gas" as the fermentation process has exhausted much or all of the substrate gas, and the system microbial biocatalyst can have produced waste gas. Inert gas can also be present. The inert gas can be part of the feed gas to the bioreactor that has substrate gas mixed with the inert gas. Inert gas that is not consumed in the fermentation exits the bioreactor in the effluent.

[0025] By removing the unused substrate gas from the broth flowing out of the bioreactor in the separator, the microbial biocatalyst is exposed to a lack of substrate gas during the time that the microorganisms are present in the separator. As the amount of gaseous substrate available to the microbial biocatalyst while in the separator is low, it is desirable to minimize the volume of the separator and thus the amount of time that the microorganisms are retained in the broth lacking sufficient gaseous substrate leading to the accumulation of nonviable microbial biomass. However, reducing the separator volume presents challenges for small, fine, and / or micro bubbles which rise more slowly in the liquid compared to large bubbles due to their smaller size. Thus, the volume required for sub-millimeter microbubbles, such as the depth to allow bubble rise, and the length required within the separator vessel from the inlet to the outlet is higher compared to conventional millimeter scale bubble separators. In some examples, the bubbles present can have a diameter of about 2 mm to about 20 mm. In another example, the bubbles present in the liquid can have a diameter of about 5 mm to about 15 mm or about 7 mm to about 13 mm. Small bubbles can have a diameter of about 3 mm to about 8 mm or about 5 mm to about 15 mm. Fine bubbles can have a diameter of about 0.1 mm to about 5 mm or about 0.2 mm to about 1.5 mm. Micro bubbles can have a diameter of about 0.05 mm to about 0.1 mm or about 0.075 mm to about 0.2 mm.

[0026] Further, the positioning of the gas separator relative to the bottom of the system reaction vessel is another embodiment of the systems and methods disclosed herein. In certain embodiments, the gas separator can be mounted or positioned as high as possible relative to the reaction vessel. By elevating the separator to the maximum possible extent, the need for an expensive valve, such as a butterfly valve or a throttle valve, between the reaction vessel outlet and the gas separator inlet is eliminated. When the gas separator is positioned near the bottom of the reaction vessel, without a proper valve, system liquid, such as fermentation broth, can be drained from the reaction vessel, particularly when the system is not temporarily running, such as during a start-up procedure. In conventional systems, a throttle valve is required between the reaction vessel and the separator to control the flow of liquid during reactor start-up, as otherwise liquid can be drained from the reaction vessel when the system is not running. By reducing the volume of the separator vessel, the weight of the gas separator is similarly reduced, and the separator can be elevated and positioned at a level near the center or upper portion of the reaction vessel. Elevating the gas separator eliminates the need for a throttle valve and significantly reduces the cost of the system. Further, the safety and reliability of the system is improved due to the reduced number and complexity of the required reactor components. However, in certain embodiments, a throttle valve can be present to control the flow of fluid between the reaction vessel and the gas separator and to facilitate proper system start-up. Additionally, positioning the separator near the center portion or upper portion of the reaction vessel reduces the pressure differential between the separator and the feed gas supply and injection point within the reaction vessel. Thus, the rate of dissolved CO2and recycled other off-gases within the reactor system can be reduced. Further, the elevated positioning of the separator provides an effective storage space for fermentation broth during unstable flow events and improves the overall operability and efficiency of the reactor.

[0027] Figure 1 A bioreactor system 100 having a conventional gas separator 120 positioned near the bottom of the reaction vessel 102 is schematically depicted. The bioreactor system 100 generally includes a reaction vessel 102 configured to include a reaction such as a fermentation process or a chemical conversion process. The bioreactor system 100 can be composed of one or more reaction vessels 102 and / or column or pipe arrangements. Suitable types of reaction vessels include, for example, continuous stirred tank reactors (CSTRs), immobilized cell reactors (ICRs), trickle bed reactors (TBRs), upflow or downflow bubble columns, airlift fermentors, static mixers, circulating loop reactors, membrane reactors such as hollow fiber membrane bioreactors (HFM BRs), or other vessels or other devices suitable for gas contact.

[0028] The bioreactor 100 can be adapted to receive a gaseous feed 108 comprising a gaseous substrate such as a Ci carbon source, which is injected in the form of bubbles into the liquid fermentation broth by the sparger 106. A Ci carbon source can refer to a one-carbon molecule that serves as a partial or sole carbon source for the microorganisms disclosed herein. For example, the Ci carbon source can comprise one or more of: CO, CO2, CH4, CH3OH, or CH2O2. In some examples, the Ci carbon source can comprise one or both of CO and CO2. Optionally, hydrogen can also be introduced. The fermentation process can include a single reaction vessel 102 or multiple reactors in parallel or in series. For example, the fermentation process can include a first growth reactor in which the bacteria are cultivated, and a second fermentation reactor into which the fermentation broth from the growth reactor can be introduced, and in which the majority of the fermentation product can be produced. Fermentation can be interpreted as a process that receives one or more gaseous substrates, such as syngas produced by gasification or industrial off-gases, or CO2 from direct air capture, and produces one or more products by utilizing one or more Ci- fixing microorganisms as biocatalysts. A "Ci-fixing microorganism" can refer to a microorganism that has the ability to produce one or more products from a Ci carbon source.Typically, the microorganisms in the bioreactor 100 can be or derived from C1- fixing bacteria such as Acetobacterium woodii, Alkalibaculum bacchii, Blautia producta, Butyribacterium methylotrophicum, Clostridium aceticum, Clostridium autoethanogenum, Clostridium carboxidivorans, Clostridium coskatii, Clostridium drakei, Clostridium formicoaceticum, Clostridium ljungdahlii, Clostridium magnum, Clostridium scatologenes, Eubacterium limosum, Moorella thermautotrophica, Moorella thermoacetica, Oxobacter pfennigii, Sporomusa ovata, Sporomusa silvacetica, Sporomusa sphaeroides, Clostridium necator, Cupriavidus necator, Thermoanaerobacter kivui, Moorella, Clostridium, Ruminococcus, Acetobacterium, Eubacterium, Butyribacterium, Oxobacter, Methanosarcina, Desulfotomaculum, Clostridium autoethanogenum, Clostridium ljungdahlii, and Clostridium ragsdalei, or combinations thereof.

[0029] The reaction vessel 102 can be a container or vessel in which one or more liquid streams or flows 101 can be introduced into the vessel 102 for subsequent gas contact, gas absorption, biological or chemical reactions, such as microbial fermentation. The fluids as disclosed herein can include a liquid, gas bubbles (including small, fine and / or microbubbles) and / or off-gas. The fluids can also include one or more cultures of microorganisms. The fermentation broth or liquid 101 can encompass any mixture of the components disclosed herein, such as a nutrient medium and one or more cultures of microorganisms. Likewise, the fermentation process can utilize fermentation to ferment gas bubbles of a gaseous substrate to produce one or more products. The microbial culture can be maintained in a liquid fermentation broth which can also contain additional nutrients, vitamins and / or minerals sufficient to allow for microbial growth.

[0030] In the reaction vessel 102, the fluids having a gas phase and a liquid phase can flow in a vertical direction. In one embodiment of the reaction vessel 102, the fluids of the gas and liquid phases can flow generally downward within the vessel 102. The reaction vessel 102 can not be limited to any particular aspect ratio (height to diameter) or to any particular material and can be constructed of any material suitable for the process, such as stainless steel or PVC. The reaction vessel 102 can include internal components, such as one or more static mixers common in biological and chemical engineering processes. The reaction vessel 102 can also be comprised of external or internal heating or cooling elements, such as a water jacket. The reaction vessel 102 can also be in fluid contact with a pump 126 to circulate the liquids, gas bubbles and / or fluids 101, 111 and 124 of the system 100.

[0031] As Figure 1As shown, liquid fermentation broth 101 enters the top of the reaction vessel 120. Gas substrate in the gas feed 108 is injected into the liquid 101 within the reaction vessel 102 through a sparger 106 connected to the gas feed 108. The sparger 106 can include at least one device to introduce gas into the liquid, the gas being injected as bubbles such as small bubbles, fine bubbles, and / or microbubbles, to agitate the gas or to dissolve the gas in the liquid. Example spargers can include orifice spargers, sintered spargers, and drilled tube spargers. The sparger 106 can be installed in a horizontal or vertical position. In some examples, the sparger 106 can be a perforated plate or ring, sintered glass, sintered steel, porous rubber tubing, porous metal tubing, porous ceramic, or stainless steel, among others. The sparger 106 can have various grades (porosities) or can include orifices of certain sizes to produce bubbles of particular sizes. The injected gas substrate bubbles can break into smaller size bubbles within the reaction vessel 102. Examples of systems and methods for producing bubbles include those described in U.S. Patent No. 9,327,251, U.S. Patent Application No. US 17 / 453,476, filed November 3, 2021, and U.S. Patent Application No. US 63 / 263,507, filed November 2, 2021, the entireties of all of which are incorporated by reference herein for all purposes.

[0032] As also shown Figure 1 The separator 120 is in fluid communication with the reaction vessel 102. Fluid 111 containing bubbles, microorganisms, and liquid exits near the bottom of the reaction vessel 102 and is controlled by a throttle valve 112. The throttle valve 112 regulates the flow of the fluid 111 into the separator 120. The separator 120 is configured to remove substrate bubbles and off-gas containing inert gas 122 from the fluid 111, and a gas stream 122 exits or is vented from the separator 120. The off-gas can generally be composed of inert gas and CO2. The liquid or fermentation broth 124, from which the gas has been removed, is recirculated by a pump 126 and re-enters the reaction vessel 102 as liquid 101. The liquid 101 can further contain biocatalysts. Additional liquid fermentation broth can be combined with the recirculated fermentation broth 124 prior to recirculation into the reaction vessel 120.

[0033] Figure 2A bioreactor system 200 is schematically depicted with a novel gas separator 220 positioned near the center or upper portion of the reaction vessel 202. Liquid 201, such as a fermentation broth, enters the top of the reaction vessel 202. A gas feed 208 containing a gaseous substrate is injected into the liquid 201 within the reaction vessel 202 through a sparger 206 connected with the gas feed 208. The gaseous substrate typically comprises a Ci carbon source that is injected through the sparger 206 in the form of gas bubbles from small to fine to microscopic in size into the liquid fermentation broth. A gas separator 220 is in fluid communication with the reaction vessel 202. Fluid 211 containing unused substrate and off-gas / inert gas bubbles as well as liquid is discharged near the bottom of the reaction vessel 202. The fluid 211 can further comprise a microbial biocatalyst. Notably, the system 200 does not have any throttling valve to regulate the flow of fluid 211 into the separator 220. However, in other examples, a throttling valve can be present. The system 200 does not require a throttling valve because due to the reduction in size and weight, the reduced volume separator 202 can be elevated to the center or upper portion of the reaction vessel 202. By elevating the separator 220, problems associated with system start-up and limiting system liquid circulation are eliminated. Also, the reduced volume separator provides a weight reduction that allows the separator 220 to be elevated. Generally, the volume of the separator 220 required for efficient and effective removal of gas can be at least 15% of the volume of the reaction vessel 202. In some examples, the volume required for the separator 220 can be, for example, at least, greater than, less than, equal to, or between any number of, about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, to 30% of the total volume of the reaction vessel 202.

[0034] Gas separator 220 can be configured to remove gas bubbles, particularly small, fine and / or micro-sized gas bubbles, from fluid 211 in a gas stream 222. Gas stream 222 exits or is discharged from the top portion of separator 220 via an outlet. Liquid stream 224, depleted of off-gas / inert gas and substrate gas, is recirculated by pump 226 and re-enters reaction vessel 202 as liquid 201. Additional liquid can be combined with recirculated liquid 224 prior to entering reaction vessel 202 when recirculated by recirculation pump 226. As previously discussed, positioning separator 220 near the center portion, upper portion or top of reaction vessel 202 reduces the pressure differential between separator 220 and gas feed 208 and distributor 206 within reaction vessel 202. In other examples, separator 220 can be positioned at approximately the midpoint of reaction vessel 202, as measured from the bottom of reaction vessel 202 to the top of reaction vessel 202. In another example, separator 220 can be positioned above at least the bottom third portion of reaction vessel 202. In yet another example, separator 220 can be positioned near the upper third portion of reaction vessel 202.

[0035] As previously discussed, systems employing conventional gas separators to remove off-gas / inert gas from a reaction liquid require a separator vessel having an increased volume to provide sufficient time for smaller gas bubbles to detach and exit the liquid. The increased volume includes a separator cylinder or vessel having increased height and length requirements to allow for slower rising velocities of smaller gas bubbles. The time required for a gas bubble to detach and exit the reaction fluid or liquid can be represented by the following equation:

[0036]

[0037] where t is the time required for a gas bubble to rise and exit the liquid, y is the height of the separator vessel, and V y is the rising velocity of the bubble. Notably, the rising velocity V y of a gas bubble is generally determined by the size of the bubble and the viscosity of the liquid fermentation broth. The smaller the bubble, the smaller the rising velocity V y and the longer the time required for the bubble to exit the liquid. The length or width of the separator required can be represented by the following equation:

[0038] L = V x x t

[0039] where L is the required length of the separator vessel, Vx is the distance that the liquid with the gas bubble is distributed from the inlet of the separator vessel to the outlet of the separator vessel. The time t can be substituted in to give the following expression:

[0040]

[0041] Thus, it is clear that for the gas bubbles of a bioreactor system, in the case of a generally constant bubble rise velocity V y , the conventional separator system must employ a separator vessel with an increased volume to allow the smaller gas bubbles sufficient time to exit the liquid. As discussed above, the lengthening of the time spent in the liquid in the absence of substrate supply can result in an increase in the nonviable microbial biomass and the required separator volume increases the size and space requirements of the overall conventional reactor system.

[0042] Figure 3 A side cross-sectional view of a gas separator and the associated liquid-fermentation broth flow pattern of the novel gas separator 320 disclosed herein is shown. The gas separator 320 can include a fluid inlet 324 in communication with a separator vessel 322. The separator vessel 322 can generally be cylindrical in shape. In other examples, the separator vessel 322 can be generally rectangular in shape. In certain examples, the separator vessel 322 can be positioned in a generally horizontal position. Alternatively, the separator vessel 322 can be positioned in a generally vertical position. In some examples, the separator vessel 322 can be pressurized. In other examples, the separator vessel 322 is unpressurized. A fluid distributor 326 is positioned within the separator vessel 320. The fluid distributor 326 is in communication with the fluid inlet 324, as shown in Figure 3 , and is configured to distribute system fluid across a plurality of inclined plates 328. The fluid distributor 326 can have a generally rectangular, square, or pentagonal cross-sectional shape. In one specific embodiment, the fluid distributor 326 has a generally rectangular cross-sectional shape. In another specific embodiment, the fluid distributor 326 has a generally square cross-sectional shape. In another specific embodiment, the bottom of the fluid distributor 326 can be V-shaped.

[0043] The fluid distributor 326 can have an open top or a closed top. In some embodiments, the fluid distributor 326 can include a plurality of apertures in the sides of the fluid distributor 326 to flush the plurality of tilted plates 328. In some examples, the fluid distributor 326 can include a plurality of apertures positioned in the bottom of the fluid distributor 326 to flush the plurality of tilted plates 328. In other embodiments, the bottom of the fluid distributor 326 has only a sufficient number of apertures to allow the washout of the cleaning fluid without a sufficient number of apertures to flush the tilted plates. In some examples, the fluid distributor 326 can include a plurality of apertures in both the sides of the fluid distributor 326 and the bottom of the fluid distributor 326 to flush the plurality of tilted plates 328. In certain examples, the apertures at the sides, the bottom, or both of the fluid distributor 326 are configured to facilitate cleaning in place (CIP) of the fluid distributor 326 to remove solid waste. The apertures can allow for proper drainage of CIP fluids and particulate waste during cleaning operations. In one embodiment, a perforated plate 332 is connected to the lower portion of the tilted plates. The perforated plate 332 serves to hold the tilted plates 328 in place. The perforated plate 332 can serve to hold the tilted plates 328 in place for even distribution of the tilted plates along the length of the fluid distributor 326.

[0044] In one embodiment, the width of the fluid distributor 326 remains constant along the length of the fluid distributor 326. In another embodiment, the width of the fluid distributor 326 proximate to the fluid inlet 324 can be wider than the width of the fluid distributor 326 at the end of the fluid distributor 326 distal to the fluid inlet 324. Configuring the fluid distributor 326 to have a wider end proximate to the fluid inlet 324 and a narrower end distal to the fluid inlet 324, the fluid distributor can serve to maintain a constant fluid velocity across the length of the fluid distributor 326 as the fluid exits the apertures in the bottom of the fluid distributor 326 and as the fluid flows out of the apertures in the sides of the fluid distributor 326. The fluid distributor 326 can include a fluid directing internal, as discussed below with reference to Figure 5

[0045] The separated gas is discharged or exits the separator vessel 322 at a gas outlet 330. In one example, the separator 320 includes at least one gas outlet 330. In certain examples, the separator 320 can also include a sparger system 333 configured to distribute the fermentation broth across a foam that can accumulate across the top portion of the separator as gas bubbles rise to the surface of the liquid. The liquid spray breaks the gas bubbles forming the foam to help the gas exit the outlet 330. The separator 320 can include a liquid outlet 334 in fluid communication with the separator vessel 322. In some examples, the separator 320 can include at least two outlets 334.

[0046] Figure 3 ​The associated liquid fermentation broth flow patterns 311, 311a, 311b, and 311c are further illustrated. The unique construction of the fluid distributor 326 prevents a "short circuit" due to excessive system crossflow velocity, which would prevent bubbles from effectively resisting the rise of the inclined plate 328. To prevent this, as discussed above, the fluid distributor 326 is positioned to fluidly contact the fluid inlet 324 to isolate the liquid flow 311, efficiently distribute the fluids 311a and 311b on the inclined plate 328, and maintain a crossflow velocity along the entire length of the fluid distributor 326. Figure 3 and Figure 4 As shown, a fluid distributor 326 can be positioned on top of and recessed within an inclined plate 328. In some examples, the fluid distributor 326 can be recessed within the inclined plate 328 such that the top portion of the fluid distributor 326 can be positioned above the top of the inclined plate 328. The inclined plate can also be flushed by fluids 311a and 311b, which exit the fluid distributor via orifices in the side of the fluid distributor 326 and / or via orifices in the bottom of the fluid distributor. This configuration allows for flushing different portions of the inclined plate 328 to promote efficient flow of bubbles and liquid. For example, the top of the inclined plate 328 can be flushed by a liquid flow 311a originating from orifices in the side of the fluid distributor 326, which extend over the top portion of the fluid distributor inclined plate 328. The lower portion of the inclined plate can be flushed by liquid 311b exiting from orifices in the side of the fluid distributor 326 located below the top portion of the inclined plate. Figure 4 As shown, the bottom of the fluid distributor 326 may be positioned approximately at or at the midpoint of the inclined plate 328. In some examples, the bottom of the fluid distributor 326 may be positioned at the upper third of the inclined plate 328. In yet another example, the bottom of the fluid distributor 326 may be positioned near the lower third of the inclined plate 328. By adjusting the volume of fluid flowing 311a from the fluid distributor 326 to flush the inclined plate 328, the fluid distributor can potentially maintain a constant crossflow velocity and a constant bubble separation velocity across the inclined plate. The fluid distributor 326 may have a top to control fluid flow and prevent liquid from splashing outside the fluid distributor 326. As an alternative optional arrangement, the fluid distributor 326 may be configured to flush the inclined plate 328 by fluid 311a overflowing from the top of the fluid distributor 326, which is opposite to or other than through orifices in the side of the fluid distributor 326.

[0047] By incorporating the unique design of the fluid distributors 326 with the unique configuration of the inclined plates 328, the volume of fluid 311a and 311b that flushes the inclined plates can be efficiently regulated in the separators 320 disclosed herein at a significantly reduced volume. For example, the length of the inclined plates 328 can be reduced by decreasing the space between the inclined plates 328, and thus the size of the entire separator vessel 322 can be reduced. The reduced space between the inclined plates 328 allows for more plates to be incorporated into the system, increasing the total surface area that facilitates the rising of the gas bubbles. As a result, the footprint of the separator 320 is reduced, thereby saving space and reducing overall costs. In some examples, the volume of fluid from the fluid distributors 326 in the sides and below the top of the inclined plates that is used to flush the inclined plates 328 can be about 30% of the total volume of fluid that flushes the inclined plates 328. According to other examples, the volume of fluid 311b from the fluid distributors 326 in the sides and below the top of the inclined plates that is used to flush the inclined plates 328 can be, for example, at least, greater than, less than, equal to, or between any number of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, and 100% of the total volume of fluid that flushes the inclined plates 328. In other examples, the volume of fluid 311a that is used to flush the inclined plates 328 via the orifices in the sides of the fluid distributors 326 and positioned above the top of the inclined plates 328 can be about 70% of the total volume of fluid that flushes the inclined plates 328.According to some examples, the volume of fluid 311a used to flush the tilted plate 328 via the orifice positioned in the side of the fluid dispenser 326 above the top of the tilted plate 328 can be, for example, at least, greater than, less than, equal to, or between about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, to 100% of the total fluid volume.

[0048] As Figure 3As shown, the inclined plates 328 can be angled in approximately the same direction. This angled orientation utilizes the Boycott effect. After the inclined plates 328 are flushed in the bioreactor with fluids 311a and 311b containing bubbles and liquid fermentation broth, the bubbles rise against the inclined plates 328 due to the Boycott effect, and the bubble-free liquid 311c flows to the bottom of the separator container 322 and is subsequently discharged from the separator container 322 via outlet 334. Outlet 334 provides two exit points for liquids (such as fermentation broth containing microbial biocatalysts) from the separator. By constructing a separator with two or more outlets 334, the residence time of microorganisms in the substrate-depleted liquid is further minimized by making the distance that liquid 311c travels to leave the separator container 322 shorter. Bubbles rising to the surface of the liquid are collected as gases in the top portion of the separator container 322 and removed from the system via gas outlet 330. In some examples, multiple inclined plates 328 can be angled from approximately 45 degrees to approximately 80 degrees relative to the horizontal axis. According to one example, multiple inclined plates may be angled relative to a horizontal axis, for example, at least, greater than, less than, equal to, or any number between about 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, and 85 degrees. In other examples, the inclined plates may include a spacing of about 25 mm to about 200 mm between the individual plates. For each inclined plate, the orientation of the angle of the inclined plate may be in the direction of fluid flow from the proximal fluid inlet 324 to the distal fluid inlet 324 or opposite to the direction of fluid flow (e.g., ...). Figure 3 (as shown) or a combination thereof. According to other examples, the inclined plate 328 may include, for example, at least, greater than, less than, equal to, or in the range of about 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, 110 mm, 115 mm, 120 mm, 125 mm, 130 mm, 135 mm, 140 mm, 145 mm, 150 mm, 1 Spacing between any number of individual plates between 55mm, 160mm, 165mm, 170mm, 175mm, 180mm, 185mm, 190mm, 195mm, 200mm, 205mm, 210mm, 215mm, 220mm, 225mm, 230mm, 235mm, 240mm, 245mm, 250mm, 255mm, 260mm, 265mm, 270mm, 275mm, 280mm, 285mm, 290mm, 295mm and 300mm.

[0049] Also as Figure 3 shown in FIG. 3, after fluid 311 has passed through and past the plurality of inclined plates 328 and the gas bubbles have risen against the inclined plates 328 to the top of the separator vessel 322, the liquid 311c is discharged via outlet 334. The liquid can be recirculated back to the top of the reaction vessel via a pump, see Figure 2 . The reduced overall size and volume of the separator 320 reduces the time that the biocatalyst microorganisms remain in the substrate-depleted liquid. As the liquid with biocatalyst microorganisms is recirculated back into the reaction vessel, fresh substrate gas is sparged into the liquid broth, providing the biocatalyst microorganisms with the required substrate and preventing premature increases in microorganism biomass that are no longer viable. Additional gas or liquid inlets or outlets can be incorporated into the gas separator 320 (not shown).

[0050] As Figure 4 shown in FIG. 3, the unique gas separator configuration incorporating the novel fluid distributor 326 and the plurality of inclined plates 328 creates an efficient fluid circulation pattern that helps the gas bubbles, particularly small, fine or micro-sized gas bubbles 413, rise out of the liquid without interference from the wash flow of liquid 311a from the fluid distributor 326. By washing a portion of the inclined plates 328 proximate to the walls of the fluid distributor 326 with the fluid 311a, the exterior of the inclined plates 328 distal to the fluid distributor 326 is largely free from interference, allowing the gas bubbles 413 to rise against the inclined plates 328 unimpeded by the wash fluid 311a. Similarly, by washing the interior of the inclined plates 328 proximate to the fluid distributor 326 with the fluid 311a exiting the sides of the fluid distributor 326, the gas bubbles 413 can rise against the exterior of the inclined plates 328 unimpeded. The liquid 311b flows down the inclined plates opposite the rising gas bubbles 413. The efficient circulation of liquid and gas bubbles allows for rapid removal of gas from the system fluid, reducing the overall volume of separator required and reducing the time that the biocatalyst microorganisms spend in substrate-depleted fluid.

[0051] Figure 5A cross-sectional top view of the fluid distributor 326 is shown. A plurality of fluid directing internals 510 are positioned within the fluid distributor 326 to facilitate uniform distribution of fluid through the apertures in the sides of the fluid distributor 326 along the length of the fluid distributor 326. In one embodiment, the fluid directing internals 510 extend from the top to the bottom of the fluid distributor 326. Securing the fluid directing internals 510 at the top and bottom, rather than the sides, of the fluid distributor 326 eliminates the obstruction of the apertures in the sides of the fluid distributor 326. Viewed from the top, the fluid directing internals 510 can have an at least partially curved shape to direct longitudinally flowing fluid through the fluid distributor to the apertures in the sides of the fluid distributor. The shape can direct the fluid through a turn in the range of about 70 degrees to about 120 degrees from the longitudinal axis of the fluid distributor. The fluid directing internals extend from an interior portion of the fluid distributor to a side of the fluid distributor, or adjacent to a side of the fluid distributor. The fluid directing internals can have a uniform size and / or shape. In one embodiment, the internals are arranged in pairs, each member of the pair in parallel position to one another; one at or adjacent to a first side 528 of the fluid distributor 326 and a corresponding internal at or adjacent to a second side 530 of the fluid distributor 326. The distance between the two internals of a pair can taper along the length of the fluid flow distributor such that the distance between the two internals of a pair is significantly less at the distal end of the fluid flow distributor as compared to at the end adjacent to the inlet. As the internals can have a uniform size, the closer the two internals of a pair are to one another, the further each internal is from the respective side of the fluid flow distributor. The uniform size and shape of the internals provide an advantage in manufacturing the system, each internal does not need to be tailored to any particular location within the fluid flow distributor. This arrangement provides for uniform distribution of fluid flow along the length of the fluid flow distributor. To facilitate installation, the fluid flow distributor and associated internals can be manufactured in multiple segments to be assembled in the field. In another embodiment, the internals are not arranged in parallel pairs, but are staggered along the length of the fluid flow distributor. The distance between the fluid directing internals 510 at or adjacent to the first side 528 of the fluid distributor and the fluid directing internals 510 at or adjacent to the second side 530 of the fluid distributor can decrease along the length of the fluid distributor 326.

[0052] Figure 6 A cross-sectional side view of another embodiment of a gas separator and associated liquid-fermentation broth flow pattern of the novel gas separator 620 disclosed herein is shown. In this embodiment, a plurality of fluid inlets 624 and a plurality of fluid distributors 626 are employed. Figure 6An exemplary set of three fluid inlets and fluid distributors is depicted, and additional embodiments may employ two, four, five, six, or more sets of fluid inlets and fluid distributors. Multiple sets of fluid inlets and fluid distributors may be oriented parallel to or perpendicular to the longitudinal axis of the separator container 322. Figure 6 An embodiment is depicted in which three sets of fluid inlets and fluid distributors are oriented perpendicular to the longitudinal axis of the separator container 322, which is cylindrical and generally horizontally positioned. Similarly, Figure 6 An inclined plate 628 is shown, oriented within the separator container 322 to mate with multiple sets of fluid inlets and fluid distributors. Figure 6 In this configuration, the inclined plate 628 has a top edge and a bottom edge parallel to the longitudinal axis of the separator container 322. When additional support structures are required due to the length of the separator container to support the fluid distributor extending along the length of the separator container, Figure 6 This implementation scheme is particularly useful. By orienting the fluid distributor across the cross-section or width of the separator container, additional support structures can be avoided.

[0053] Figure 7 It shows Figure 6 A cross-sectional end view of the embodiment. In this embodiment, multiple fluid inlets 624 and multiple fluid distributors 626 are employed. Figure 7 An inclined plate 628 is clearly depicted, which is oriented within the separator container 322 to engage with multiple sets of fluid inlets and fluid distributors via top and bottom edges having a longitudinal axis parallel to the separator container 322.

[0054] Figure 8 It shows Figure 6 A cross-sectional top view of the embodiment. In this embodiment, multiple fluid inlets 624 and multiple fluid distributors 626 are employed. Figure 8 A fluid distributor 626 is clearly depicted, oriented to span the cross-section or width of the separator container 322. Figure 8 Also shown is a sprayer system 333 having multiple sprayers dispersed in an area of ​​a separator container 322.

[0055] Figure 6 , Figure 7 and Figure 8 Zhongyu Figure 3 Compared to keeping the same reference numerals in the attached figures, as shown in the references Figure 3 As described.

[0056] The gas separator systems disclosed herein can be integrated in or with various reactor systems, for example, as described in U.S. Patent No. 9,327,251, U.S. Patent Application No. US 17 / 453,476, filed November 3, 2021, and U.S. Patent Application No. US 63 / 263,507, filed November 2, 2021, the entire contents of each of these patents are incorporated herein by reference for all purposes. The bioreactor system can include a reaction vessel for containing a fluid comprising biocatalyst microorganisms, liquid microorganism growth medium, off-gas / inert gas, and a gas substrate. In some examples, the reaction vessel can employ a plurality of liquid jets produced by a multi-orifice plate that accelerates the liquid fermentation broth to break substrate gas bubbles into smaller substrate gas bubbles. The resulting liquid fermentation broth flows down the reaction vessel in a form of a downflow. Other embodiments employ an upflow in the reactor vessel.

[0057] In some examples, the substrate gas bubbles can be a Ci carbon source that is fermented by the system biocatalyst microorganisms to produce useful fermentation products and off-gas. The substrate and / or Ci carbon source can be off-gas obtained as a byproduct of an industrial process or off-gas from another source, such as internal combustion engine exhaust, biogas or landfill gas, direct air capture, or off-gas from electrolysis. The substrate and / or Ci carbon source can be syngas generated by pyrolysis, torrefaction, or gasification. In other words, the peak carbon in waste material can be recycled by pyrolysis, torrefaction, or gasification to produce syngas used as the substrate and / or Ci carbon source. The substrate and / or Ci carbon source can be a gas comprising methane, and in certain embodiments, the substrate and / or Ci carbon source can be a non-waste gas.

[0058] In certain embodiments, the industrial process is selected from the group consisting of ferrous metal product manufacturing such as steel manufacturing, non-ferrous metal product manufacturing, petroleum refining, power production, carbon black production, paper and pulp manufacturing, ammonia production, methanol production, coke manufacturing, petrochemical production, carbohydrate fermentation, cement manufacturing, aerobic digestion, anaerobic digestion, catalytic processes, natural gas extraction, cellulosic fermentation, oil extraction, industrial processing of geological reservoirs, processing of fossil resources such as natural gas, coal, petroleum, landfill operations, or any combination thereof. Examples of specific processing steps within the industrial process include catalyst regeneration, fluid catalyst cracking, and catalyst regeneration. Air separation and direct air capture are other suitable industrial processes. Specific examples in steel and iron alloy manufacturing include direct reduction of blast furnace gas, basic oxygen furnace gas, coke oven gas, top gas of iron furnaces, and residual gas from smelting iron. Other general examples include flue gas from combustion boilers and fired heaters such as natural gas, petroleum, or coal-fired boilers or heaters, and gas turbine exhaust. In these embodiments, the substrate and / or Ci carbon source can be captured from the industrial process using any known method before it is emitted into the atmosphere.

[0059] The substrate and / or Ci carbon source can be a synthesis gas, known as syngas, which can be obtained from reforming, partial oxidation, plasma, or gasification processes. Examples of gasification processes include gasification of coal, gasification of refinery residues, gasification of petroleum coke, gasification of biomass, gasification of lignocellulosic materials, gasification of waste wood, gasification of black liquor, gasification of municipal solid waste, gasification of municipal liquid waste, gasification of industrial solid waste, gasification of industrial liquid waste, gasification of refuse derived fuel, gasification of sewage, gasification of sewage sludge, gasification of sludge from wastewater treatment, gasification of landfill gas, gasification of biogas, such as when biogas is added to enhance gasification of another material. Examples of reforming processes include steam methane reforming, steam naphtha reforming, natural gas reforming, biogas reforming, landfill gas reforming, coke oven gas reforming, pyrolysis off-gas reforming, ethylene production off-gas reforming, naphtha reforming, and dry methane reforming. Examples of partial oxidation processes include thermal and catalytic partial oxidation processes, catalytic partial oxidation of natural gas, partial oxidation of hydrocarbons, partial oxidation of biogas, partial oxidation of landfill gas, or partial oxidation of pyrolysis off-gas. Examples of municipal solid waste include tires, plastics, refuse derived fuel, and fibers such as in shoes, clothing, and textiles. Municipal solid waste can be simply landfill type waste and can be sorted or unsorted. Examples of biomass can include lignocellulosic materials and microbial biomass. Lignocellulosic materials can include agricultural waste and forest waste.

[0060] The substrate and / or Ci carbon source can be a gas stream comprising methane. Such methane-containing gas can be obtained from fossil methane emissions, such as during fracking, wastewater treatment, livestock, agriculture, and municipal solid waste landfills. It is also contemplated that methane can be combusted to produce electricity or heat, and the Ci byproducts can be used as a substrate or carbon source. In other examples, the substrate can further comprise other non-carbon components, such as H2or N2.

[0061] The biocatalyst microorganisms in the bioreactor system fermentation broth can ferment the Ci carbon source and produce one or more products, such as ethanol, acetate, 1 -butanol, butyrate, 2,3-butanediol, lactate, butene, ethylene, butadiene, methyl ethyl ketone (MEK), acetone, isopropyl alcohol, lipids, 3-hydroxypropionate, terpenes (including isoprene), fatty acids, 2-butanol, 1,2-propanediol, 1-propanol, 1-hexanol, 1-octanol, branched acid salt derived products, 3-hydroxybutyrate, 1,3-butanediol, 2-hydroxyisobutyrate or 2-hydroxyisobutyric acid, isobutylene, adipic acid, 1,3-hexanediol, 3-methyl-2-butanol, 2-buten-1-ol, isovalerate, isopentanol, monoethylene glycol, or combinations thereof. In certain examples, the microbial biomass itself can be considered a product, and can be further processed to produce at least a portion of a protein source, such as in animal feed. One or more of these products can be further converted to produce other products, such as at least one component of diesel, aviation fuel, gasoline, polymeric products, and / or precursors, ingredients, or components of consumer or industrial materials.

[0062] Although the present disclosure has been described in certain specific embodiments, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that within the scope of the present disclosure, the disclosure can be practiced otherwise than is specifically described. Thus, embodiments of the present disclosure should be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the present disclosure is to be indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalents are intended to be embraced therein. All references cited herein, including publications, patent applications, and patents, are hereby incorporated by reference in their entirety as if each had been individually incorporated. All temperatures herein are in degrees Celsius and all parts and percentages are by weight unless otherwise specified.

[0063] The present disclosure is described below in connection with specific embodiments, which are intended to illustrate, but not limit, the scope of the disclosure and the claims.

[0064] A first embodiment of the present disclosure is a system for separating a gas from a liquid, the system comprising: a separator vessel; at least one fluid inlet interfacing with the separator vessel; at least one gas outlet interfacing with the separator vessel; at least one liquid outlet interfacing with the separator vessel; a plurality of inclined plates positioned within the separator vessel; and at least one fluid distributor positioned within the separator vessel and interfacing with the plurality of inclined plates, the fluid distributor further comprising a first end proximal to the fluid inlet and a second end distal to the fluid inlet. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the fluid distributor further comprises a plurality of apertures positioned on both sides of the fluid distributor. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the fluid distributor further comprises a plurality of fluid directing internals housed within the fluid distributor. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the fluid distributor further comprises a rectangular cross-section. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the fluid distributor further comprises an upper portion positioned above the top of the plurality of inclined plates and a lower portion positioned above the bottom portion of the plurality of inclined plates. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the separator vessel is cylindrical. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the cylindrical separator vessel is oriented on a horizontal plane. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the cylindrical separator vessel is in fluid communication with a reaction vessel and is positioned above at least one third of the bottom of the reaction vessel. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the plurality of inclined plates further comprise a spacing of about 25 mm to 200 mm between each plate. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the plurality of inclined plates are angled at about 45 degrees to about 80 degrees relative to a horizontal axis. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the inclined plates have a bottom portion that interfaces with a perforated plate. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the fluid inlet is positioned at one end of the cylindrical separator vessel. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein the fluid inlet is positioned along the length of the cylindrical separator vessel. One embodiment of the present disclosure is one, any one of, or all of the embodiments described in this paragraph, wherein at least two fluid inlets are positioned along the length of the cylindrical separator vessel, and wherein the system comprises at least two fluid distributors.One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, the system further comprising at least one sparger system positioned within the separator vessel.

[0065] One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, the method further comprising pressurizing the separator vessel, wherein the separator vessel is cylindrical. One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, the method further comprising positioning the cylindrical separator vessel on a horizontal plane. One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, wherein uniformly washing the plurality of inclined plates comprises passing the fluid through a plurality of orifices positioned on a side, a bottom, or both of the fluid distributor. One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, wherein a first volume of fluid passes through orifices positioned above a top of the plurality of inclined plates and a second volume of fluid passes through orifices positioned below a top of the inclined plates. One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, wherein the first volume of fluid washing the plurality of inclined plates comprises about 30% of a total liquid volume and the second volume of fluid washing the plurality of inclined plates comprises about 70% of a total liquid volume. One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, the method further comprising maintaining a constant cross-flow velocity and a constant bubble separation velocity across the plurality of inclined plates. One embodiment of the present disclosure is one, any, or all embodiments described in this paragraph, the method further comprising recycling the discharged liquid to a reactor.

[0066] A third embodiment of the present disclosure is a bioreactor system, the system comprising: a reactor vessel, the reactor vessel comprising: a fluid, the fluid comprising a liquid growth medium, a gaseous substrate comprising at least one Ci carbon source, a waste gas, and a culture of at least one microorganism in the liquid growth medium, wherein the culture of the at least one microorganism ferments the gaseous substrate to produce at least one fermentation product and the waste gas; a gas separator vessel in fluid communication with the reactor vessel and positioned above a bottom third portion of the reactor vessel, the gas separator comprising: at least one fluid inlet in fluid communication with the reactor vessel; at least one gas outlet; at least one liquid outlet; a plurality of inclined plates positioned within the gas separation vessel; and at least one fluid distributor in engagement with the plurality of inclined plates; and a pump configured to recirculate liquid comprising the liquid growth medium and the culture of the at least one microorganism from the gas separator vessel to the reactor vessel, wherein the system is pressurized, and wherein the system lacks a throttling valve between the reactor vessel and the gas separator vessel fluid inlet.

Claims

1. A system for separating a gas from a liquid, the system comprising: Separator container; At least one fluid inlet, said fluid inlet being engaged with the separator container; At least one gas outlet, said gas outlet being connected to the separator container; At least one liquid outlet, said liquid outlet being connected to the separator container; Multiple inclined plates, the inclined plates being positioned within the separator container; and At least one fluid distributor is positioned within the separator container and engages with the plurality of inclined plates, the fluid distributor further comprising a first end adjacent to the fluid inlet and a second end distal to the fluid inlet; The fluid dispenser is positioned above the top of the inclined plate and recessed within the inclined plate.

2. The system according to claim 1, wherein the fluid distributor further comprises a plurality of orifices positioned on both sides of the fluid distributor.

3. The system of claim 1, wherein the fluid distributor further comprises a plurality of fluid guiding internals housed within the fluid distributor.

4. The system of claim 3, wherein the fluid distributor further comprises a rectangular cross-section.

5. The system of claim 4, wherein the fluid dispenser further comprises an upper portion positioned above the top of the plurality of inclined plates and a lower portion positioned above the bottom of the plurality of inclined plates.

6. The system of claim 1, wherein the separator container is cylindrical.

7. The system of claim 6, wherein the cylindrical separator container is in fluid communication with the reaction vessel and is positioned above at least the bottom third of the reaction vessel.

8. The system of claim 1, wherein the plurality of inclined plates further includes a spacing of 25 mm to 200 mm between the plates.

9. The system of claim 1, wherein the plurality of tilting plates are at an angle of 45 to 80 degrees relative to the horizontal axis.

10. The system of claim 1, wherein the inclined plate has a bottom portion that engages the perforated plate.

11. The system of claim 6, wherein the fluid inlet is located at one end of the cylindrical separator container.

12. The system of claim 6, wherein the fluid inlet is positioned along the length of the cylindrical separator container.

13. The system of claim 6, wherein at least two fluid inlets are positioned along the length of the cylindrical separator container, and wherein the system includes at least two fluid distributors.

14. The system of claim 1, further comprising at least one sprayer system positioned within the separator container.

15. A method for separating a gas from a liquid using the system of any one of claims 1 to 14, the method comprising: A fluid containing liquid and gas is supplied to at least one inlet of the separator container; The fluid is delivered from the inlet to a fluid distributor located within the separator container; The fluid within the fluid distributor is guided and flushed evenly through orifices in the fluid distributor to a plurality of inclined plates positioned within the separator container and along the length of the fluid distributor. The gas rises against the plurality of inclined plates; The liquid is discharged through at least one liquid outlet; as well as The gas is removed through at least one gas outlet.

16. The method of claim 15, the method further comprising pressurizing the separator container, wherein the separator container is cylindrical.

17. The method of claim 16, the method further comprising positioning the cylindrical separator container on a horizontal plane.

18. The method of claim 15, wherein uniformly flushing the plurality of inclined plates comprises passing the fluid through a plurality of orifices located on the side, bottom, or both of the fluid distributor.

19. The method of claim 18, wherein a first volume of fluid passes through an orifice positioned above the top of the plurality of inclined plates, and a second volume of fluid passes through an orifice positioned below the top of the inclined plates.

20. The method of claim 19, wherein the fluid rinsing the first volume of the plurality of inclined plates accounts for 30% of the total liquid volume, and the fluid rinsing the second volume of the plurality of inclined plates accounts for 70% of the total liquid volume.

21. The method of claim 15, the method further comprising maintaining a constant crossflow velocity and a constant bubble separation velocity across the plurality of inclined plates.

22. The method of claim 15, further comprising recycling the discharged liquid back into the reactor.

23. A bioreactor system, the bioreactor system comprising: The reaction vessel includes: A fluid comprising a liquid growth medium, a gaseous substrate containing at least one C1 carbon source, an exhaust gas, and a culture of at least one microorganism in the liquid growth medium, wherein the culture of the at least one microorganism ferments the gaseous substrate to produce at least one fermentation product and the exhaust gas. A gas separator container, which is in fluid communication with the reaction vessel and positioned above the bottom third of the reactor vessel, the gas separator comprising: At least one fluid inlet, the fluid inlet being in fluid communication with the reaction vessel; At least one gas outlet; At least one liquid outlet; Multiple inclined plates, the inclined plates being positioned within the gas separation container; and At least one fluid dispenser engages with the plurality of inclined plates, wherein the fluid dispenser is positioned above the top of the inclined plates and recessed within the inclined plates; and A pump configured to recirculate liquid comprising the liquid growth medium and the culture of at least one microorganism from the gas separator container to the reaction vessel, wherein the system is pressurized and wherein the system lacks a throttling valve between the reaction vessel and the fluid inlet of the gas separator container.

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