D-psicose Crystallization via Controlled Cooling and Chromatography

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for producing high purity D-psicose crystals are costly and inefficient, requiring large amounts of ethanol and yeast fermentation, which increases production costs and results in low crystal grain size and purity, making mass production challenging due to the difficulty in separating crystals from mother liquor and issues with marketability.

Innovation Solution

A method involving continuous chromatography to separate and purify D-psicose solutions without yeast fermentation, using a process that includes removing impurities, concentrating, and rapidly cooling the solution to induce crystallization, thereby producing high purity D-psicose crystals with a grain size of MA200 or more without the use of organic solvents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If yeast fermentation is used to remove unreacted D-fructose, then D-fructose is removed from the solution, but production costs increase and unreacted D-fructose cannot be reused

Engineering Contradiction:

Improveremoval of unreacted D-fructoseVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and removes unreacted D-fructose and by-products from the D-psicose solution through chromatography, separating them from the desired product. This allows for selective removal of impurities while maintaining the ability to reuse the separated D-fructose in subsequent reactions, thereby reducing production costs while achieving reliable purification.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If a large amount of ethanol is added to the crystallization process, then D-psicose crystals can be obtained, but subsidiary material costs increase and explosion prevention facilities are required

Engineering Contradiction:

Improvecrystal formationVSAvoidproduction cost and safety requirements

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the crystallization parameters by using controlled cooling temperature and concentration conditions instead of adding large amounts of ethanol. By adjusting the temperature to maintain supersaturation in the metastable zone and controlling the concentration, the patent achieves crystal formation without requiring expensive ethanol additives or special explosion prevention facilities.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If conventional cooling crystallization is used, then crystals can form, but crystal grain size is small and separation from mother liquor is difficult

Engineering Contradiction:

Improvecrystal formationVSAvoidcrystal separation efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent employs dynamic control of the crystallization process by maintaining the solution in the metastable zone through controlled cooling rates and temperature fluctuations. This dynamic approach allows crystals to grow larger over time rather than forming rapidly as fine grains, making them easier to separate from the mother liquor and improving overall productivity.

Inventive Principle:

Principle #15Dynamics

4Speed

If rapid cooling is used to induce crystallization, then crystals form quickly, but novel crystal nucleation increases and crystal growth is inhibited

Engineering Contradiction:

Improvecrystallization rateVSAvoidcrystal growth quality

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The patent uses periodic or controlled cooling action to maintain the solution in the metastable zone, allowing crystals to grow steadily rather than forming rapidly through excessive nucleation. This controlled periodic cooling ensures both reasonable crystallization speed and high crystal growth quality by preventing the solution from becoming too supersaturated.

Inventive Principle:

Principle #19Periodic action

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 method reduces production costs, achieves high purity D-psicose crystals of 98% or more, and improves marketability by enhancing crystal grain size and separation from mother liquor, facilitating industrial-scale production.

Implementation Method 1

cooling the concentrated D-psicose solution to 30° C. to 40° C. through a heat exchanger

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

utilize the principle of inducing crystal growth in a metastable zone (region) of supersaturation

Methodology Applied

Scientific EffectSupersaturation: Supersaturation

Data Source

PatentUS10808002B2Method for preparing D-psicose crystal

Publication Date: 2020.10.20 CJ CHEILJEDANG CORP

AI summary

A method for producing high purity D-psicose crystals having a purity of 98% (w/w) or more and a grain size of MA200 or more. The method includes: removing impurities from a D-psicose solution to obtain a purified D-psicose solution; concentrating the purified D-psicose solution; cooling the concentrated D-psicose solution to 30° C. to 40° C. through a heat exchanger; seed crystallizing the D-psicose solution at 30° C. to 40° C. to obtain a seed crystallized massecuite; and full-scale crystallizing the seed crystallized massecuite. The method can produce pure D-psicose crystals in a suitable form for industrial application through an economical crystallization process from the D-psicose solution without using organic solvents.