Fermentation Feedstock Separation for Alcohol Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing alcohols through fermentation, such as liquid-liquid extraction, are hindered by the presence of undissolved solids in the feedstock, leading to reduced efficiency, increased costs, and contamination issues due to interference with mass transfer and phase separation.
Innovation Solution
A process that separates feedstock components into an aqueous stream, an oil stream, and a solid stream, allowing for controlled recombination or removal, thereby improving fermentation productivity and co-product profiles by minimizing undissolved solids and oil in the fermentation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid-liquid extraction is used to remove alcohol from fermentor, then alcohol production efficiency is improved, but undissolved solids in feedstock interfere with mass transfer and phase separation, reducing extraction efficiency
Solution Approach 1:
The patent applies preliminary action by removing undissolved solids from the feedstock before fermentation begins. This pre-treatment step ensures that when liquid-liquid extraction is subsequently applied, there are no solids to interfere with mass transfer or phase separation, thus maintaining high extraction efficiency throughout the process.
Solution Approach 2:
The patent applies the extraction principle by removing undissolved solids from the feedstock stream before fermentation. This extraction of harmful solids prevents them from interfering with subsequent liquid-liquid extraction operations, ensuring reliable mass transfer and phase separation.
2Quantity of substance
If undissolved solids are present in fermentation broth, then feedstock utilization is maintained, but mass transfer coefficient decreases and phase separation is impeded
Solution Approach 1:
The patent removes undissolved solids from feedstock before fermentation begins, preventing their negative impact on mass transfer coefficient while maintaining feedstock utilization through proper processing of the remaining soluble components.
3Quantity of substance
If oil is present in feedstock, then energy content is increased, but oil accumulates in extractant and reduces extraction efficiency over time
Solution Approach 1:
The patent applies extraction by removing oil from the feedstock before fermentation. This prevents oil from accumulating in the extractant during liquid-liquid extraction operations, thereby maintaining extraction efficiency over extended operation periods while still utilizing the energy content through alternative means.
Solution Approach 2:
The patent converts the harmful effect of oil accumulation into a benefit by removing oil beforehand, which prevents extraction efficiency degradation. The removed oil can potentially be utilized separately for energy purposes, transforming a problematic component into a separate resource.
4Reliability
If undissolved solids are removed from feedstock, then liquid-liquid extraction efficiency is improved, but additional separation equipment and processing steps are required
Solution Approach 1:
The patent applies preliminary action by implementing a solids removal step before fermentation, which simplifies subsequent extraction operations. While this adds one separation step, it eliminates the need for complex modifications to extraction equipment and ensures reliable operation throughout the process.
5Productivity
If oil is removed from feedstock, then extraction efficiency is maintained, but additional processing steps and energy requirements are introduced
Solution Approach 1:
The patent applies extraction to remove oil from feedstock before fermentation, maintaining extraction efficiency throughout operation. The energy investment in this preliminary oil removal is offset by avoiding extraction efficiency degradation and extended operational life of the extraction system.
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 enhances alcohol production efficiency, reduces energy requirements, and increases fermentor volume efficiency by removing undissolved solids and oil, leading to improved co-product compositions and cost savings.
Implementation Method 1
separating the feedstock slurry to form an aqueous solution, a wet cake, and an oil stream
Implementation Method 2
adding the aqueous solution to a fermentation broth to produce a fermentation product
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to processes and systems for the production of fermentation products such as alcohols. The present invention also provides methods for separating feed stream components for improved biomass processing and productivity.