Fermentation Broth Dehydration via Direct Heating and Membrane Separation
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Solution Overview
Problem
Current methods for preparing organic vapor-phase dehydration feedstocks from fermentation broths are time-consuming, costly, and environmentally polluting, as they require multiple steps for impurity removal and use of chemicals like ion exchange resins.
Innovation Solution
A method involving direct heating of the fermentation broth to concentrate and vaporize organic compounds, separating impurities and organic vapor-phase dehydration feedstocks under controlled temperatures, allowing for continuous vapor-phase dehydration reactions without additional impurity removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple impurity removal steps (centrifugation, ultrafiltration, nanofiltration, ion exchange, salt removal) are used to remove organic impurities from fermentation broth, then impurity removal effectiveness is improved, but process complexity and operation cost increase significantly
Solution Approach 1:
The patent combines multiple impurity removal steps (centrifugation, ultrafiltration, nanofiltration, ion exchange, salt removal) into a single integrated membrane separation process. This merging of functions reduces device complexity and operation cost while maintaining effective impurity removal, directly resolving the technical contradiction between removal effectiveness and process complexity.
Solution Approach 2:
The membrane separation system performs multiple functions simultaneously: it acts as a centrifuge for solid-liquid separation, an ultrafiltration membrane for macromolecule removal, a nanofiltration membrane for salt separation, and an ion exchange medium. This multi-functionality eliminates the need for separate devices for each impurity removal step, reducing overall process complexity while maintaining comprehensive impurity removal effectiveness.
2Manufacturing precision
If ion exchange resin and chromatography are used for impurity removal, then impurity removal effectiveness is improved, but environmental pollution problems arise and commercial applicability decreases
Solution Approach 1:
The patent extracts and eliminates the use of ion exchange resins and chromatography agents from the impurity removal process. By replacing these chemical-based methods with physical membrane separation, the harmful environmental factors associated with resin disposal and chemical waste are removed, while impurity removal effectiveness is maintained through the selective permeability of the membrane system.
Solution Approach 2:
The patent replaces expensive and environmentally problematic ion exchange resins with disposable or easily regenerable membrane elements. The membrane system uses physical barriers rather than consumable chemical agents, eliminating the need for costly resin replacement and complex regeneration processes, thereby reducing environmental pollution while maintaining effective impurity removal.
3Manufacturing precision
If large amounts of acidic and basic solutions are used for pH adjustment and metal salt removal, then impurity removal effectiveness is improved, but environmental pollution increases and operation cost rises
Solution Approach 1:
The patent replaces chemical-based impurity removal methods (acidic and basic solutions for pH adjustment and metal salt removal) with a mechanical/physical membrane separation system. The membranes physically separate impurities based on size and charge without requiring large amounts of chemical agents, thereby eliminating environmental pollution from chemical waste while maintaining effective impurity removal.
Solution Approach 2:
The membrane separation system performs pH adjustment and metal salt removal functions inherently through its physical and chemical properties, without requiring external acidic or basic solutions. The membrane's selective permeability and charge characteristics enable it to automatically separate different types of impurities, making the process self-sufficient and free from harmful chemical byproducts.
4Manufacturing precision
If a multi-step impurity removal process is used, then impurity removal effectiveness is improved, but time consumption and operation cost increase
Solution Approach 1:
The patent merges multiple sequential impurity removal steps (centrifugation, ultrafiltration, nanofiltration, ion exchange, salt removal) into a single integrated membrane separation operation. This consolidation reduces the total processing time significantly while maintaining the cumulative impurity removal effectiveness of all individual steps, directly addressing the contradiction between removal effectiveness and time consumption.
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 approach simplifies impurity removal and reduces energy and operational costs, eliminating environmental pollution by integrating impurity removal and vaporization into a single step, enabling efficient conversion of organic compounds to unsaturated hydrocarbons.
Implementation Method 1
concentrating a fermentation broth containing a low concentration of an organic compound by direct heating at a temperature of 100° C. or lower under a vacuum
Implementation Method 2
concentrating a fermentation broth containing a low concentration of an organic compound by direct heating at a temperature of 100° C. or lower under a vacuum
Implementation Method 3
heating a concentrated fermentation broth of the step of (a) to a temperature of 100 to 250° C. thereby vaporizing the remaining water and the organic compound
Implementation Method 4
heating a concentrated fermentation broth of the step of (a) to a temperature of 100 to 250° C. thereby vaporizing the remaining water and the organic compound
Implementation Method 5
separating a vaporized organic compound of the step of (b) from impurities present in the fermentation broth
Data Source
AI summary
The present invention relates to a method including: directly heating a fermentation broth to remove impurities, thereby preparing an organic vapor-phase dehydration feedstock; and continuously subjecting the organic vapor-phase dehydration feedstock to a vapor-phase dehydration reaction. According to the present invention, impurities in a fermentation broth, which have been removed by a multi-step process in the prior art, can be completely removed in a single-step process, and thus the time, cost and energy required for a process for preparing an organic vapor-phase dehydration feedstock from the fermentation broth can be effectively reduced, and the process for preparing the organic vapor-phase dehydration feedstock and a vapor-phase dehydration reaction can be continuously performed in an effective manner.