Fiber Conduit Contactor Extraction for Fermentation Broths
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Solution Overview
Problem
Current chemical extraction methods are inefficient, costly, and generate hazardous byproducts, particularly in processes like hydrodesulfurization and rare earth element separation, which require multiple stages and result in significant waste and operational challenges due to the formation of gelatinous emulsions known as 'crud'.
Innovation Solution
The use of fiber conduit reactors/contactors to facilitate extraction by introducing a first stream with an extractant proximate to fibers within a conduit reactor, where a second immiscible stream is introduced to interact and extract chemical compounds or elements, minimizing waste and byproduct formation through high surface area mass transfer and laminar flow, which reduces crud formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solvent extraction methods are used, then chemical species can be extracted from fluid streams, but the process requires long mixing and settling times, uses hazardous chemicals, and generates significant waste
Solution Approach 1:
The invention segments the extraction process into discrete functional zones within the column: a mixing zone where extractant and feed stream are combined, a settling zone where phases separate, and a discharge zone. This segmentation enables continuous extraction without long mixing and settling times by providing dedicated spaces for each function to occur efficiently and simultaneously
Solution Approach 2:
The invention introduces an extractant as an intermediary substance that facilitates the transfer of chemical species from the feed stream to the raffinate stream. The extractant acts as a mediator that enables selective extraction through controlled chemical interactions, allowing efficient separation without requiring long contact times or hazardous conditions
2Manufacturing precision
If multiple extraction stages are used to separate metal elements, then separation precision improves, but device complexity and processing time increase significantly
Solution Approach 1:
The invention transitions from horizontal multi-stage extraction systems to a vertical single-column system. By stacking functional zones (mixing, settling, discharge) vertically within a single column, the system achieves multi-stage separation capability in one integrated unit, reducing device complexity while maintaining separation precision through controlled vertical flow patterns
3Productivity
If conventional extraction processes are used, then chemical species are extracted, but hazardous byproducts and crud formation occur requiring careful handling and disposal
Solution Approach 1:
The invention extracts and removes the harmful crud byproduct from the extraction system by designing a discharge zone that allows continuous removal of accumulated crud. This prevents crud buildup that would otherwise interfere with phase separation and reduce extraction efficiency, while the extracted crud can be handled separately rather than mixed with product streams
Solution Approach 2:
The invention changes the physical parameters of the extraction process by controlling flow rates, phase densities, and interfacial tensions to optimize separation efficiency. By adjusting these parameters, the system achieves effective extraction while minimizing the formation of hazardous emulsions and crud, and facilitates easier handling of byproducts
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 enables fast, efficient extraction of metals and compounds with reduced byproduct formation, smaller equipment footprints, and lower operational costs by leveraging high surface area mass transfer and minimizing crud formation, thus improving the scalability and efficiency of chemical extraction processes.
Implementation Method 1
high surface area mass transfer
Implementation Method 2
introducing a first stream comprising an extractant proximate a plurality of fibers positioned within a conduit reactor and extending proximate to one or more collection vessels. The method further includes introducing a second stream into the conduit reactor proximate to the plurality of fibers, wherein the second stream is in contact with and is substantially immiscible with the first stream
Data Source
AI summary
Processes are provided which utilize fiber conduit reactors/contactors to effect extraction from a fluid stream, particularly a fermentation broth, a waste stream of a fermentation process, a fluid comprising a dye, or a fluid comprising a pharmaceutical compound. In particular, methods are provided which include introducing a first stream comprising an extractant and a second stream which is substantially immiscible with the first stream into a conduit reactor proximate a plurality of fibers. The streams are introduced into the conduit reactor such that they are in contact with each other and the extractant of the first stream interacts with the second stream to extract a fermentation product, a fermentation byproduct, a dye or a pharmaceutical compound from the second stream into the first stream. The method further includes receiving the first and second streams in collection vessel/s and withdrawing separately the first and second streams from collection vessel/s.