Integrated Bioreactor Separation for Continuous Product Recovery
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Solution Overview
Problem
Existing biocatalytic processes face challenges in efficiently recovering organic substances from complex reaction mixtures, particularly at low concentrations, due to limitations in reactor design, oxygen supply, and emulsion formation, leading to reduced production rates and product losses.
Innovation Solution
A bioreactor system with integrated reaction and separation compartments allows simultaneous production and separation of organic substances using turbulent flow conditions and controlled droplet sizes, maintaining optimal extraction and separation rates by matching In Situ Product Recovery (ISPR) power and Separation Capacity (SC) through controlled addition and removal of a product recovery phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate production and separation processes are used, then product recovery is achieved, but productivity is reduced due to multiple processing steps and time loss
Solution Approach 1:
The patent combines the production reactor and separation apparatus into a single integrated bioreactor system. The reaction mixture flows continuously from the production section through the separation section, allowing simultaneous production and separation operations. This eliminates the need for separate processing equipment and reduces transfer time between stages, directly resolving the contradiction between productivity and device complexity.
Solution Approach 2:
The system maintains continuous operation throughout the entire process. Substrate is continuously fed to the biocatalyst, product is continuously formed and immediately extracted into the recovery phase, and the reaction mixture continuously flows through separation. This continuous action eliminates idle time between production and separation, maximizing volumetric production rate without requiring complex batch processing equipment.
2Productivity
If product concentration is increased to maintain production capacity, then output is maintained, but product inhibition and degeneration increase
Solution Approach 1:
The system continuously extracts the produced organic substance from the reaction mixture as it forms, transferring it into a separate recovery phase. This removal of product from the aqueous reaction environment prevents product inhibition of the biocatalyst and reduces product degeneration, while maintaining high production capacity through continuous extraction and flow.
Solution Approach 2:
The recovery phase acts as an intermediary medium that receives and sequesters the produced organic substance. By using this intermediate phase, the system separates the product from the reaction environment, allowing high production rates without exposing the biocatalyst to inhibitory product concentrations.
3Productivity
If turbulent flow conditions are used to maintain droplet dispersion, then mass transfer is enhanced, but energy consumption increases
Solution Approach 1:
The system uses dynamic flow conditions rather than static mixing. The reaction mixture flows continuously through the apparatus, and droplets are dispersed and maintained through the flow dynamics and recirculation pattern. This dynamic approach achieves effective mass transfer without requiring continuous high-energy agitation, as the flow itself provides the necessary mixing and dispersion.
Solution Approach 2:
The system employs hydraulic flow to achieve droplet dispersion and maintain mass transfer. By using the flow of liquid itself to create and maintain the dispersed phase, the system avoids the need for mechanical agitation devices that would consume additional energy, while still achieving effective mass transfer through controlled flow conditions.
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 enhances production capacity by maintaining high recovery rates and low substance concentrations, achieving up to 100-fold increases in daily production and enabling continuous processing with reduced inhibitory effects on biocatalysts.
Implementation Method 1
a product recovery phase is present (typically dispersed in the continuous aqueous phase) into which the organic substance migrates
Implementation Method 2
the organic substance is produced using a biocatalyst
Implementation Method 3
produce organic substances by fermentation. In such a fermentation process, micro-organisms are used to convert a suitable substrate into an organic substance of interest
Data Source
AI summary
The invention relates to a method for recovering a biocatalytically produced organic substance from a reaction mixture, comprising—providing a reaction mixture, wherein the organic substance is produced using a biocatalyst, which reaction mixture comprises a substrate for the biocatalyst in a continuous aqueous phase, and wherein further a product recovery phase is present into which the organic substance migrates or onto which the organic substance absorbs or adsorbs; and—separating the product recovery phase comprising the produced substance from the aqueous phase and the biocatalyst. The invention further relates to a bioreactor system for biocatalytically producing a substance, comprising an apparatus, said apparatus comprising a reaction compartment (11) situated in a lower part of the apparatus and a separator compartment (9).