Fermentation Foam Control via Gas Void Fraction Measurement
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Solution Overview
Problem
Current fermentation processes face inefficiencies in detecting foam levels in tanks and accurately controlling defoamer addition, leading to excessive defoamer use and wasteful costs.
Innovation Solution
A system comprising a SONAR-based entrained air measurement device and signal processor that measures the speed of sound in a fermentation mixture to determine foam levels and control defoamer addition based on entrained air levels, optimizing foam control within the tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If foam sensors or level probes are used to detect foam levels, then foam detection capability is provided, but measurement accuracy is poor leading to excessive defoamer addition
Solution Approach 1:
The patent replaces mechanical foam sensors and level probes with a gas void fraction measurement system that uses acoustic or other non-contact measurement techniques. This substitution provides more accurate measurement of the actual gas content in the fermentation mixture, enabling precise control of defoamer addition and eliminating the need for excessive defoamer use that occurs with inaccurate mechanical sensing.
Solution Approach 2:
The patent implements a feedback control system where gas void fraction measurements are continuously monitored and used to adjust defoamer addition rates. The measurement signal feeds back to the control system, which modulates defoamer dosing to maintain optimal foam control. This closed-loop feedback eliminates the open-loop excessive dosing that occurs with traditional sensing methods.
2Reliability
If excess defoamer is added to ensure no foam indication, then foam control reliability is improved, but defoamer cost increases
Solution Approach 1:
The feedback control system continuously monitors gas void fraction and adjusts defoamer addition in real-time, providing reliable foam control only when necessary. This eliminates the need for continuous excess defoamer addition, maintaining reliability while reducing overall consumption.
Solution Approach 2:
The system transitions from static excess defoamer dosing to dynamic, condition-based dosing. Defoamer addition is continuously adjusted based on actual gas void fraction measurements, providing reliability during high foam conditions while minimizing consumption during low foam conditions.
3Device complexity
If traditional foam detection methods are used, then system complexity is low, but defoamer control precision is poor
Solution Approach 1:
The patent replaces simple mechanical foam sensors with advanced gas void fraction measurement systems that provide precise control capability. The increased measurement precision enables precise defoamer addition control, overcoming the limitation of simple mechanical systems.
Solution Approach 2:
The system measures and controls a different parameter (gas void fraction) rather than direct foam level. This parameter change provides more accurate information about the actual gas content in the mixture, enabling more precise defoamer addition control.
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 allows for precise control of foam production, reducing defoamer usage and associated costs by accurately measuring entrained air and adjusting defoamer amounts in real-time.
Implementation Method 1
measuring a speed of sound propagating through a sample of a mixture forming part of a fermentation process in a tank
Data Source
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AI summary
A technique related to a fermentation process; where a signal processor receives a signal containing information about an amount of entrained air in a mixture forming part of a fermentation process in a tank; and determines a level of foam in the tank based at least partly on the amount of entrained air in the mixture. The signal processor may also provide a control signal for controlling an amount of defoamer (or antiforming agent) added to the mixture in the tank so as to control the production of foam within the tank by controlling the amount of defoamer added to the mixture in the tank.