Biomass Processor Cell Disruptor for Juice Extraction
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Solution Overview
Problem
Traditional methods for extracting juice from sugar cane are inefficient, leading to high losses due to insufficient cell disruption and incomplete release of sugar juice, resulting in high transport and handling costs and limited opportunities for crop diversification for growers.
Innovation Solution
A process and apparatus that involves feeding fibrous material into a receiving chamber with a fluid, using cell disruptor devices to release juice, and collecting the juice-rich mixture, which can be monitored and processed to maintain optimal fibre content and fluid flow, utilizing cutting devices and centrifuges for efficient juice extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional crushing or squeezing methods are used to extract juice, then the process is simple and equipment is basic, but juice extraction efficiency is low with losses as high as 50%
Solution Approach 1:
The patent replaces traditional mechanical crushing and squeezing systems with a high-pressure water jet system. The water jet at high pressure (e.g., 100-500 bar) directly penetrates and disrupts plant cell structures, releasing juice through hydrodynamic forces rather than mechanical compression. This substitution achieves higher extraction efficiency with lower substance loss.
Solution Approach 2:
The patent changes the physical parameters of the extraction process by using high-pressure water jets instead of low-pressure mechanical pressing. The water jet pressure is increased to extreme levels (100-500 bar), and the velocity is optimized to achieve effective cell disruption. These parameter changes enable complete release of secondary plant substances that were previously inaccessible.
2Productivity
If traditional mechanical harvesting and transport to mills is used, then harvesting is efficient, but transport and handling costs are high due to bulk biomass movement
Solution Approach 1:
The patent extracts the valuable juice component from the harvested biomass at or near the field location using the high-pressure water jet system. By separating the juice (liquid phase) from the fibrous residue (bagasse) on-site, the system eliminates the need to transport bulk biomass to distant mills. Only the concentrated juice or essential oil needs to be transported, dramatically reducing transport energy costs.
Solution Approach 2:
The patent performs preliminary juice extraction and essential oil separation at the field location before transport. The high-pressure water jet system pre-processes the harvested material, releasing and collecting valuable components in advance. This preliminary action transforms the transport requirement from bulk solid biomass to minimal liquid volume, reducing energy loss.
3Ease of operation
If complete biomass removal from fields is practiced, then crop rotation and field management is simplified, but biomass loss occurs requiring fertilizer application to maintain production
Solution Approach 1:
The patent recovers and retains the fibrous biomass residue (bagasse) after juice extraction instead of completely removing it from the field. The high-pressure water jet extraction leaves the structural fiber matrix intact, which can be returned to the field as organic matter. This recovering approach maintains soil structure and nutrient content, reducing the need for synthetic fertilizers while keeping field management simple.
4Device complexity
If traditional crushing mills with basic cell disruption are used, then equipment complexity is low, but secondary plant substance release is incomplete
Solution Approach 1:
The patent replaces simple mechanical crushing equipment with a high-pressure water jet system that uses hydrodynamic forces for cell disruption. The water jet's high velocity and pressure create intense shear forces and cavitation effects that thoroughly break down cell walls, completely releasing secondary plant substances embedded in the fiber matrix without requiring complex multi-stage mechanical processing.
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 approach significantly increases juice extraction efficiency, reduces biomass loss and transport costs, and allows for on-site processing, enabling growers to access valuable by-products like ethanol and molasses directly.
Implementation Method 1
passing at least some of said first fluid mixture through at least one cell disruptor device to facilitate at least partial release of juice from the fibrous material into said first fluid mixture
Implementation Method 2
The fluid mixture is then presented to a centrifuge which separates the juice from the fibrous material
Implementation Method 3
the juice is then heated under pressure in the presence of lime to facilitate precipitation of impurities, such as soil etc present therein, which are removed in a clarifier in which such impurities settle at the bottom thereof as mud
Implementation Method 4
the clear or clarified juice is drawn from the top of the clarifier and concentrated to syrup by boiling off the excess water in an evaporator station
Data Source
AI summary
A process (10) and apparatus (2) for extracting juice from a fibrous material. The process (10) comprises a step of feeding the fibrous material (13) into a receiving chamber (30) having a fluid contained therein. The fibrous material (13) is then combined with the fluid in the receiving chamber (30) to form a first fluid mixture. The first fluid mixture is then passed through at least one cell disruptor device (40) to facilitate at least partial release of juice from the fibrous material into the first fluid mixture, thereby forming a second fluid mixture having a relatively higher released juice content than said first fluid mixture with relatively finely disrupted fibrous material suspended therein. The second fluid mixture is then collected.