Continuous Enzymatic Hydrolysis of Cellulosic Biomass
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Solution Overview
Problem
Current methods for enzymatic hydrolysis of cellulosic biomass with high solid content face challenges in achieving efficient mixing due to high viscosity, leading to energy-intensive and complex reactor designs, and require long hydrolysis times, which are costly and inefficient.
Innovation Solution
A continuous process involving a reactor system where cellulosic biomass with high solid content is continuously added and partially hydrolyzed biomass is removed, maintaining a steady state with controlled viscosity below 25 Pa·s, allowing for efficient enzymatic hydrolysis without the need for complex stirring and reducing enzyme consumption through recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If high solid content cellulosic biomass is used for enzymatic hydrolysis, then water and energy consumption are reduced, but the viscosity of the slurry increases making mixing difficult
Solution Approach 1:
The patent implements a dynamic continuous process where biomass is continuously fed and hydrolyzed product is continuously removed, allowing the system to maintain optimal viscosity conditions throughout operation. This dynamic approach replaces static batch processing, enabling high solids content processing without the viscosity buildup that plagues batch systems.
Solution Approach 2:
The patent extracts the hydrolyzed product from the reactor continuously, removing it from the high-viscosity environment. By taking out the converted material as it forms, the system prevents viscosity accumulation and maintains mixability throughout the reaction process, solving the mixing difficulty associated with high solids content.
2Manufacturing precision
If conventional batch processes are used for high solid content biomass, then complete hydrolysis can be achieved, but the process requires energy demanding and complex machinery
Solution Approach 1:
The patent employs continuous enzymatic hydrolysis where biomass continuously flows through the reactor system, maintaining constant hydrolytic action. This continuous process achieves complete hydrolysis through prolonged exposure to enzymes without requiring complex batch processing equipment, simplifying the overall system design.
Solution Approach 2:
The patent replaces complex mechanical mixing systems with a flow-based continuous process. Instead of using energy-demanding stirrers and agitators required in batch systems, the continuous flow mechanism inherently provides mixing through fluid dynamics, eliminating the need for complex mechanical mixing machinery.
3Quantity of substance
If long hydrolysis times are used to ensure complete conversion, then glucose yield increases, but process cost and time consumption increase
Solution Approach 1:
The continuous flow system maintains constant enzymatic action on fresh biomass as it passes through the reactor, achieving complete hydrolysis in a continuous manner rather than requiring extended batch processing time. The continuous renewal of substrate-enzyme contact maintains high conversion rates throughout the process.
Solution Approach 2:
The system performs preliminary hydrolysis in the first reactor stage, converting a portion of the biomass before the material proceeds to subsequent stages. This staged approach begins the conversion process early and continues it systematically, achieving complete glucose yield without requiring excessive total processing time.
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 process enables commercially viable enzymatic hydrolysis at high solids loading with reduced energy consumption, lower enzyme requirements, and increased glucose yield, using a cascade of reactors to maintain viscosity control and facilitate enzyme recycling.
Implementation Method 1
performing at least a partial enzymatic hydrolysis of the cellulosic biomass in said reactor
Implementation Method 2
adding a predetermined amount of enzymes to said reactor; performing at least a partial enzymatic hydrolysis
Data Source
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AI summary
The present invention relates to a continuous process for the enzymatic hydrolysis of cellulosic biomass and to an apparatus for conducting said process. According to the present invention, a steady state is achieved in a reactor in regard to the hydrolysis reaction. Therein, cellulosic biomass of a high total solids content (preferably 10% or higher, further preferably between 15 and 30%) is continually added to said reactor, while at least partially hydrolyzed cellulosic biomass is continually removed from said reactor. The steady state is adjusted, i.e. the amount of cellulosic biomass added and the amount of at least partially hydrolyzed cellulosic biomass removed is adjusted, so that the retention time of a given portion of added cellulosic biomass in the reactor is longer than its "liquefaction time", i.e. the time period required to transform a solid slurry into a pumpable liquid during hydrolysis, i.e. the time required to lower the viscosity of the slurry to a value, which is acceptable for further processing.