D-psicose Crystallization via Seed Cooling and Chromatography
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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 fine grain crystals that are difficult to separate and market, due to D-psicose's challenging crystallization properties.
Innovation Solution
A method involving continuous chromatography to remove impurities, concentrating the D-psicose solution, and cooling it with seed crystals to induce crystal growth, eliminating the need for organic solvents and enabling larger grain size and higher purity D-psicose crystals without yeast fermentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of ethanol is used for crystallization, then D-psicose crystals can be obtained, but production costs increase and facilities for explosion prevention and ethanol recovery are required
Solution Approach 1:
The invention changes the crystallization parameters by using water instead of ethanol as the solvent, and by controlling the concentration of D-psicose solution within a specific range (60-80% w/w) to achieve effective crystallization without requiring special facilities for explosion prevention or ethanol recovery
Solution Approach 2:
The invention replaces expensive ethanol with water, which is a cheap and safe solvent that does not require special handling facilities, thereby reducing both direct material costs and infrastructure investment
2Reliability
If a large amount of ethanol is added to the crystallization process, then D-psicose crystals can be obtained, but subsidiary material costs increase
Solution Approach 1:
The invention replaces expensive ethanol with water, which is a cheap solvent, thereby significantly reducing subsidiary material costs while maintaining crystallization effectiveness
3Manufacturing precision
If yeast fermentation is used to remove unreacted D-fructose, then D-psicose reaction solution can be purified, but unreacted D-fructose cannot be reutilized and production costs increase
Solution Approach 1:
The invention extracts and removes unreacted D-fructose from the reaction solution through chromatography, separating it from D-psicose while maintaining high purity, and enables the extracted D-fructose to be reutilized in other processes
Solution Approach 2:
Instead of discarding unreacted D-fructose through yeast fermentation, the invention recovers it through chromatography separation, allowing for its reutilization and reducing production costs
4Productivity
If D-psicose solution is concentrated to high supersaturation, then crystal nucleation occurs, but crystal growth is inhibited due to increased population
Solution Approach 1:
The invention performs preliminary concentration of D-psicose solution to a specific supersaturation range (60-80% w/w) before crystallization, and controls the cooling rate to prevent excessive nucleation, thereby ensuring both efficient crystal formation and adequate crystal growth
Solution Approach 2:
The invention dynamically controls the concentration and temperature parameters during the crystallization process, adjusting the supersaturation level and cooling rate to balance crystal nucleation and growth, preventing excessive population while maintaining productivity
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 with a grain size of MA 200 or more, and improves marketability by efficiently separating crystals from the mother liquor, facilitating mass production.
Implementation Method 1
concentrating the purified D-psicose solution to a supersaturated concentration
Implementation Method 2
cooling the concentrated D-psicose solution to 30°C to 40°C
Implementation Method 3
seed crystallizing the D-psicose solution by adding a seed crystal of D-psicose and increasing the crystal size
Implementation Method 4
When a seed crystal is added, however, crystal growth can occur, thereby increasing crystal size
Data Source
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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.