Fermentation Process at Reduced Pressure for Water Removal
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Solution Overview
Problem
Conventional fermentation processes face issues with surplus water, leading to yield loss and the need for large, expensive equipment for water removal, as well as inefficient heat management and potential contamination from low-boiling contaminants.
Innovation Solution
The fermentation process is conducted at reduced pressure below atmospheric pressure, allowing for significant water evaporation and removal, concentrating the product streams and efficiently managing heat through vacuum application, while maintaining the reaction medium in a liquid phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If water removal steps are implemented to address surplus water, then product concentration is improved, but product yield is reduced due to liquid product removal
Solution Approach 1:
The patent applies vacuum evaporation to remove water from the fermentation broth by transitioning water from liquid to vapor phase. This selective phase transition allows water removal while keeping the non-volatile fermentation product in the liquid phase, thus concentrating the product without removing it from the system.
Solution Approach 2:
The patent changes the pressure parameter by applying vacuum conditions during fermentation. This pressure reduction lowers the boiling point of water, enabling evaporation at lower temperatures that do not damage the product or microorganisms, while selectively removing water vapor without removing the fermentation product.
2Quantity of substance
If large amounts of water are removed using conventional equipment, then product concentration is improved, but equipment cost and complexity increase
Solution Approach 1:
The patent employs the fermentation process itself to generate the heat required for water evaporation. The exothermic nature of fermentation provides the necessary thermal energy, eliminating or reducing the need for external heating equipment and energy input for water removal.
Solution Approach 2:
By utilizing the phase transition of water from liquid to vapor under vacuum conditions, the patent achieves water removal using simple evaporation principles rather than complex mechanical separation equipment, reducing equipment costs and operational complexity.
3Temperature
If conventional heat removal methods are used to manage fermentation heat, then temperature control is improved, but energy efficiency is reduced
Solution Approach 1:
The patent converts the harmful effect of excess heat generated during fermentation into a beneficial effect by utilizing this heat to drive water evaporation under vacuum conditions. The heat that would otherwise need to be removed is instead used to concentrate the fermentation broth, improving energy efficiency.
Solution Approach 2:
The phase transition of water from liquid to vapor absorbs the excess heat generated during fermentation, providing passive temperature control while simultaneously concentrating the product solution. This dual function eliminates the need for separate cooling systems.
4Productivity
If fermentation is conducted at reduced pressure, then water evaporation and removal is improved, but risk of contamination increases
Solution Approach 1:
The patent maintains a controlled atmosphere during vacuum fermentation, typically using inert gas sparging or maintaining sterile conditions within the vacuum system. This prevents contamination while allowing vacuum conditions to be applied for water removal.
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 results in increased product yield, reduced water content, and improved fermentation quality by removing surplus water and contaminants, without accompanying product loss, and allows for the use of low-quality waste heat, making the process more efficient and cost-effective.
Implementation Method 1
water being evaporated and removed from the reactor during the fermentation
Implementation Method 2
the fermentation process is carried out at a pressure which is below atmospheric pressure
Implementation Method 3
the application of a vacuum results in evaporation of liquid, and this leads to the removal of heat from the system
Data Source
AI summary
The present invention pertains to a fermentation process wherein a carbohydrate source is contacted under fermentation conditions with a microorganism in an aqueous fermentation broth to form a fermentation product which is a salt or a product with a boiling point above the boiling point of water, wherein the fermentation process is carried out at; a pressure which is below atmospheric pressure and at least at the value where the reaction medium is at its boiling point at the fermentation temperature, with water being evaporated and removed from the reactor during the fermentation in an amount which is at least 20% of the volume of liquid present in the reactor at the start of the fermentation. It has been found that effecting a fermentation process at reduced pressure while removing a substantial amount of water has a number of advantages. It solves the problem of having a surplus of water in the system, it ensures removal of reaction heat, and may lead to improved fermentation quality.