Closed-Loop Organic Acid Recovery from Plant Pretreatment
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Solution Overview
Problem
Existing organic acid pretreatment processes for plant materials face inefficiencies in recovering and reusing organic acids, leading to significant operational costs and environmental impacts, with challenges in separating and purifying cellulose, lignin, and hemicellulose, and the lack of productive use for fermentation by-products.
Innovation Solution
A combination of dryer and desolventizer is used to reduce organic acid content in cellulosic pulp, neutralization and alkalization minimize sodium hydroxide use, centrifugation for lignin separation, evaporation and stripping for hemicellulosic juice production, and multi-column distillation for high water content solutions, along with converting stillage to organic fertilizer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If organic acids pretreatment process is used to dissolve hemicellulose and lignin, then cellulose separation is achieved, but organic acids are lost and operational costs increase
Solution Approach 1:
The patent implements a recovery system where organic acids from the extraction liquor are distilled and recovered, then reused in subsequent pretreatment cycles. This transforms the previously discarded organic acids into reusable resources, directly reducing substance loss and operational costs while maintaining processing efficiency
Solution Approach 2:
The patent establishes a feedback loop where the output of one process stage (organic acids in extraction liquor) becomes the input for the recovery system, which in turn feeds recovered organic acids back into the pretreatment process. This closed-loop system ensures continuous optimization and reduces waste
2Reliability
If sodium hydroxide is used for neutralization and alkalization of cellulose, then lignin elimination is improved, but sodium hydroxide consumption increases operational costs
Solution Approach 1:
The patent applies partial neutralization followed by controlled alkalization, using precisely the amount of sodium hydroxide needed to achieve the desired pH range for enzymatic hydrolysis. This avoids excessive chemical usage while ensuring sufficient lignin elimination, reducing chemical consumption without compromising effectiveness
Solution Approach 2:
The patent optimizes the pH parameters through controlled neutralization and alkalization steps, adjusting the chemical dosage to achieve the optimal pH range (typically pH 10-12 for alkalization) required for effective lignin removal and subsequent enzymatic hydrolysis, minimizing chemical consumption while maintaining process reliability
3Loss of substance
If multi-column distillation is used for organic acids recovery, then recovery efficiency is improved, but energy and water consumption increase
Solution Approach 1:
The patent divides the distillation process into multiple columns, each optimized for specific separation tasks. This segmentation allows for more efficient recovery of organic acids at different concentration levels, improving overall recovery efficiency while enabling better energy management through staged processing
Solution Approach 2:
The patent designs the distillation system to handle multiple streams (extraction liquor, washing waters, process condensates) simultaneously, making the system multi-functional. This universality improves organic acids recovery from various sources while optimizing energy and water usage across the entire system
4Device complexity
If fermentation by-products (stillage) are disposed of as waste, then processing simplicity is maintained, but environmental impact increases and valuable resources are lost
Solution Approach 1:
The patent transforms the harmful waste product (stillage) into a beneficial resource by using it as substrate for organic acid production through fermentation. This converts an environmental liability into a valuable chemical feedstock, eliminating pollution while creating additional revenue streams
Solution Approach 2:
The patent implements a system where fermentation by-products are automatically utilized within the same processing facility for organic acid production. This self-service approach eliminates the need for external waste disposal systems while creating internal resource circulation, reducing environmental impact without adding external processing complexity
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
Enhances recovery and reuse of organic acids, reduces sodium hydroxide consumption, decreases water and energy consumption, and transforms waste into valuable products, achieving economic and environmental benefits.
Implementation Method 1
uses the dryer to reduce the organic acids to a content of 5% to 12%, calculated from the total weight of the dried cellulosic pulp
Implementation Method 2
a desolventizer is used to further remove the organic acids using direct steam as the desolventizing medium to reduce the organic acid content to less than 2%
Implementation Method 3
separating and cleaning lignin from a lignin suspension derived from organic acids pretreatment of plant materials
Implementation Method 4
evaporation and stripping for hemicellulosic juice production
Implementation Method 5
evaporation and stripping for hemicellulosic juice production
Implementation Method 6
multi-column distillation for high water content solutions
Data Source
AI summary
The invention is directed to compositions and processes concerning efficient downstream processing of products derived from organic acids pretreatment of plant materials.