Aqueous Fermentation Feedstock via Enzymatic Hydrolysis and Microfiltration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost of fermentation feedstock is a significant contributor to the overall cost of fermentation products, necessitating the development of low-cost feedstock and efficient production methods.
Innovation Solution
An aqueous fermentation feedstock comprising glucose and dextrose oligomers, produced by treating corn kernels with alpha-amylase enzymes and optionally gluco-amylase, followed by microfiltration to separate water-soluble and water-insoluble carbohydrates, which are then used to culture organisms for single-cell protein and ethanol production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional fermentation feedstock is used, then fermentation products can be produced, but the cost of fermentation feedstock is high
Solution Approach 1:
The patent changes the chemical composition parameters of the feedstock by controlling glucose concentration (40-150 g/L), dextrose oligomers concentration (50-300 g/L), and particle size distribution through microfiltration. This creates a optimized carbohydrate composition that improves fermentation efficiency while controlling costs.
Solution Approach 2:
The patent employs microfiltration membranes with specific pore sizes to separate and control particle size distribution in the feedstock. This creates a standardized particle size range that optimizes microbial uptake while simplifying downstream processing.
2Stability of the object's composition
If corn kernels are comminuted and treated with enzymes to produce aqueous feedstock, then feedstock composition is optimized, but processing time and temperature requirements increase
Solution Approach 1:
The patent optimizes enzymatic treatment by controlling temperature (>150°F) and duration (30-300 minutes) parameters to achieve optimal hydrolysis of starch to glucose and dextrose oligomers. This controlled parameter approach ensures consistent carbohydrate composition while managing processing time.
Solution Approach 2:
The patent performs preliminary comminution of corn kernels before enzymatic treatment to increase surface area and accessibility. This preliminary mechanical action reduces the subsequent enzymatic treatment time required to achieve the desired carbohydrate composition.
3Manufacturing precision
If microfiltration is used to separate water-soluble and water-insoluble carbohydrates, then feedstock purity is improved, but equipment complexity increases
Solution Approach 1:
The patent uses microfiltration membranes with controlled pore sizes to achieve precise separation of water-soluble carbohydrates (permeate) from water-insoluble carbohydrates (retentate). The porous membrane structure provides the necessary separation precision while maintaining a relatively simple system configuration.
Solution Approach 2:
The patent segments the carbohydrate mixture into two distinct fractions through microfiltration: a water-soluble carbohydrate-rich permeate and a water-insoluble carbohydrate-rich retentate. This segmentation enables targeted use of each fraction for different fermentation applications.
4Productivity
If particle size is reduced to less than 0.5 micron, then microbial uptake efficiency is improved, but energy consumption for comminution increases
Solution Approach 1:
The patent uses microfiltration membranes with pore sizes in the range of 0.01-0.5 micron to size-select particles in the feedstock. This porous filtration approach achieves the desired fine particle size distribution for optimal microbial uptake without requiring excessive mechanical comminution energy input.
Solution Approach 2:
The patent replaces intensive mechanical comminution with enzymatic hydrolysis and controlled microfiltration to achieve fine particle sizes. This substitution reduces mechanical energy consumption while maintaining or improving particle size quality for microbial uptake.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces the cost of fermentation feedstock by creating a cost-effective aqueous feedstock with specific composition ranges, enabling efficient production of single-cell protein and ethanol while maintaining sterility and optimal particle sizes.
Implementation Method 1
treating said slurry with alpha-amylase enzymes and optionally also with gluco-amylase, at a temperature greater than 150 degrees Fahrenheit, whereby a corn mash is formed, wherein said corn mash comprises water soluble carbohydrates and water-insoluble carbohydrates
Implementation Method 2
filtering at least a fraction of said corn mash as a filtration feed on a microfiltration membrane; whereby an aqueous filtration permeate, comprising said water-soluble carbohydrates, and a filtration retentate comprising said water-insoluble carbohydrates, are formed
Data Source
AI summary
Aqueous fermentation feedstock and method of producing same. The feedstock includes glucose and dextrose oligomers, wherein (i) glucose concentration is in a range between 10 gram/Liter (g/L) and 150 g/L; (ii) dextrose oligomers concentration is in a range between 50 g/L and 300 g/L; and optionally (iii) slurried particles of less than 0.5 micron; (iv) slurried particles of more than 0.5 micron, wherein a content of such suspended particles of more than 0.5 micron is less than 30 g/L; (v) ash at a concentration in a range between 20 g/L and 50 g/L; (vi) lactate at a concentration in a range between 0.5 g/L and 10 g/L; (vii) protein at a concentration in a range between 5 g/L and 50 g/L; (viii) corn oil at a concentration of less than 10 g/L; and/or (ix) glycerol at a concentration in a range between 1 g/L and 30 g/L.