Bioreactor Gas Transfer via Segmentation and Inversion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing bioreactors and bioprocesses face limitations in efficiently utilizing gaseous electron donors, electron acceptors, and carbon sources for microbial cultures, particularly in the chemosynthetic fixation of CO2 into longer chain organic compounds, leading to suboptimal energy density and economic feasibility issues in biofuel production.

Innovation Solution

A bioreactor design that efficiently mixes and recirculates gases, such as H2, CO2, and O2, into a liquid medium to enhance gas transfer and utilization, minimizing net gas flows and optimizing oxygen levels for the production of higher energy density biofuels like biodiesel and biojet fuel, using oxyhydrogen microorganisms for carbon fixation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional bioreactors are used for microbial cultures requiring gaseous electron donors and carbon sources, then the system structure is simple, but gas transfer efficiency is low

Engineering Contradiction:

Improvegas transfer efficiencyVSAvoidbioreactor structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The bioreactor is divided into multiple compartments including a gas sparging zone, a reaction zone, and a separation zone. Gas is introduced through distributed spargers throughout the liquid phase rather than a single point, creating multiple gas-liquid contact interfaces that enhance mass transfer efficiency while maintaining manageable system complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A three-phase slurry system is introduced as an intermediary mechanism, where solid catalyst particles serve as carriers for gas dissolution and reaction. The slurry circulates between the reaction zone and a separation zone, mediating the transfer of gaseous electron donors and carbon sources to the microbial culture while enhancing gas-liquid-solid mass transfer

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If photosynthesis is used to fix CO2 into biomass, then the process is well-established, but it requires light and open environments which are prone to contamination and weather damage

Engineering Contradiction:

Improveprocess stabilityVSAvoidenvironmental control

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Instead of using photosynthesis (light-driven CO2 fixation), the system employs chemosynthesis where microorganisms fix CO2 using chemical energy from gaseous electron donors (H2, CO, CH4) in a dark, closed bioreactor environment. This inverts the energy source from light to chemical substrates, enabling reliable operation in controlled indoor settings without exposure to weather or contamination risks

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The bioreactor operates as a closed system with controlled atmosphere, introducing gaseous electron donors and carbon sources in an inert, controlled environment. This protects the microbial culture from external contamination and weather conditions while maintaining stable reaction conditions for reliable CO2 fixation

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Ease of manufacture

If syngas or producer gas is used as carbon source, then low cost feedstocks can be utilized, but gas composition control becomes complex

Engineering Contradiction:

Improvefeedstock costVSAvoidgas composition control

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The system is designed to accommodate variable gas compositions by adjusting operational parameters such as gas flow rates, sparging intensity, and liquid circulation rates. The microbial culture adapts to different electron donor and carbon source ratios, allowing the use of low-cost syngas or producer gas from various feedstocks without requiring precise gas composition control

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The bioreactor system can process multiple types of gaseous substrates (H2, CO, CO2, CH4) simultaneously or separately, making it universally applicable to different syngas compositions from various feedstocks including biomass, waste, or fossil sources. This multi-functionality eliminates the need for feedstock-specific reactor designs

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If carbon fixation processes are implemented, then CO2 can be converted to valuable products, but energy density of produced fuels remains suboptimal

Engineering Contradiction:

Improveenergy densityVSAvoideconomic feasibility

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The system produces hydrocarbons that replicate the molecular structure and energy density characteristics of fossil fuels. By synthesizing longer-chain hydrocarbons through chemosynthetic carbon fixation, the produced biofuels can directly replace conventional fuels in existing infrastructure without requiring separate distribution systems, thereby achieving both high energy density and economic feasibility

Inventive Principle:

Principle #26Copying

Data Source

PatentUS10696941B2Method and apparatus for growing microbial cultures that require gaseous electron donors, electron acceptors, carbon sources, or other nutrients

Publication Date: 2020.06.30 KIVERDI INC

AI summary

Compositions and methods and apparatus for growth and maintenance of microorganisms and/or bioprocesses using one or more gases as electron donors, electron acceptors, carbon sources, or other nutrients, and for a bioprocess that converts hydrogen and carbon dioxide, or syngas, or producer gas into lipid products, bio-based oils, or other biochemical products.