Biosurfactant Fermentation Reactor with Oxygenation and Recirculation
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Solution Overview
Problem
Current methods for producing biosurfactants, such as surfactin from Bacillus subtilis, do not yield sufficiently high concentrations to be economically viable for industrial-scale production and often require costly ingredients and apparatuses, while also facing contamination risks that necessitate the use of preservatives.
Innovation Solution
A system and process involving a reactor with oxygenation, agitation, and recirculation modules to ferment a mixture of foamate and aqueous biosurfactant from Bacillus subtilis, achieving high concentrations of biosurfactants and eliminating the need for preservatives by maintaining a controlled environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If current methods are used to produce biosurfactants, then production can be achieved, but the concentration is insufficient for economic viability
Solution Approach 1:
The patent changes key fermentation parameters including using specific carbon sources (foamate), controlling pH (6.5-7.5), temperature (30-37°C), and dissolved oxygen levels to optimize biosurfactant production. These parameter changes enable achieving concentrations of 25-75 ppm surfactin, making the process economically viable.
Solution Approach 2:
The patent implements continuous fermentation processes with recirculation systems that maintain optimal conditions throughout the fermentation period. The continuous supply of foamate and maintenance of foam layer ensures sustained high-level biosurfactant production without interruption.
2Quantity of substance
If high cost ingredients or apparatuses are used, then production can be achieved, but cost efficiency decreases
Solution Approach 1:
The patent uses inexpensive, readily available materials such as foamate (a byproduct of foam generation), standard bacterial strains (Bacillus subtilis), and conventional fermentation equipment. This eliminates the need for expensive specialized apparatuses or rare ingredients, significantly reducing production costs.
Solution Approach 2:
The fermentation process utilizes the natural metabolic capabilities of Bacillus subtilis to convert foamate into biosurfactants. The system leverages the bacteria's inherent enzymatic pathways and growth characteristics, requiring minimal external intervention or expensive additives to achieve high yields.
3Reliability
If preservatives are added to control contamination, then contamination can be controlled, but product purity decreases
Solution Approach 1:
The patent maintains a controlled fermentation environment with specific pH (6.5-7.5), temperature (30-37°C), and dissolved oxygen levels that are unfavorable for contaminant growth. The continuous recirculation and foam layer maintenance create a stable, protective environment that prevents contamination without requiring chemical preservatives.
Solution Approach 2:
The patent converts the potential harm of contamination into a benefit by using competitive exclusion principles. The high-density culture of Bacillus subtilis produces antimicrobial substances (iturins, fengycins) that naturally inhibit contaminants, turning the challenge of contamination control into an additional mechanism for product purification.
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
The system produces a highly concentrated biosurfactant foamate, enhancing cost efficiency and product consistency, while minimizing contamination risks and eliminating the need for preservatives, thus enabling the creation of effective disinfectant formulations.
Implementation Method 1
an oxygenation module arranged to oxygenate the mixture of foamate and aqueous biosurfactant
Implementation Method 2
an agitation module arranged to agitate the mixture of foamate and aqueous biosurfactant
Implementation Method 3
a recirculation module arranged to recirculate the mixture of foamate and aqueous biosurfactant
Implementation Method 4
the at least one reactor being arranged to ferment the mixture of foamate and aqueous biosurfactant into a concentrated foamate of biosurfactant
Data Source
AI summary
The present invention generally relates to a system and process for producing a biosurfactant, and more particularly to a system and process for producing a biosurfactant from at least one strain of Bacillus subtilis, and formulations which comprise the biosurfactant.