Fiber Reactor System Ethanol Production
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Solution Overview
Problem
Existing systems for processing cellulose and hemicellulose materials do not effectively produce an ethanol-laden fiber stream for low ethanol beer stripping systems, lacking the necessary efficiency and features.
Innovation Solution
A system and method involving a fiber reactor system where cellulose and hemicellulose materials are sterilized, mixed with microorganisms and micronutrients, and processed to produce an ethanol-laden fiber stream through a series of steps including sterilization, filtration, and fermentation, ultimately generating a stream with 2-8% wt ethanol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing systems process cellulose and hemicellulose materials, then basic processing is achieved, but they cannot effectively produce an ethanol-laden fiber stream for low ethanol beer stripping systems
Solution Approach 1:
The system changes physical and chemical parameters including temperature (sterilization at elevated temperatures), pH levels, and chemical concentrations (micronutrients, vitamins) to optimize microbial fermentation and ethanol production from cellulose and hemicellulose materials
Solution Approach 2:
The invention uses composite microbial cultures comprising multiple species (Cellulomonas, Clostridium, Bacillus, Lactobacillus, Saccharomyces) working together to simultaneously degrade cellulose, hemicellulose, and starch while producing ethanol, achieving synergistic effects that neither single organism could achieve alone
2Productivity
If the system processes large volumes of fiber slurry, then throughput is increased, but sterilization and contamination control become more difficult
Solution Approach 1:
The system performs preliminary sterilization of the fiber slurry before fermentation by heating to elevated temperatures and maintaining for specified periods, eliminating contaminants before they can compromise the fermentation process during high-volume processing
Solution Approach 2:
The system creates a protected fermentation environment by pre-sterilizing materials and maintaining controlled conditions throughout the process, cushioning against potential contamination that could disrupt ethanol production in large-volume operations
3Productivity
If the system uses multiple processing steps including sterilization, filtration, and fermentation, then ethanol production efficiency is improved, but system complexity increases
Solution Approach 1:
The system combines multiple functions into integrated units: the sterilization system merges heating and holding functions; the filtration system combines solid-liquid separation and sterilization; the fermentation system integrates anaerobic digestion and ethanol production, reducing overall system complexity while maintaining high ethanol production efficiency
Solution Approach 2:
The fiber slurry processing system performs multiple functions sequentially: sterilization, cooling, fermentation, and filtration through an integrated series of interconnected tanks and systems, where each unit handles multiple operational requirements (heating, holding, cooling, mixing) within a single equipment platform
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
The system efficiently produces an ethanol-laden fiber stream suitable for low ethanol beer stripping systems, with a sugar product generated as a byproduct that can be used for other high-value applications.
Implementation Method 1
sterilization, mixed with microorganisms and micronutrients, and processed
Implementation Method 2
processed to produce an ethanol-laden fiber stream through a series of steps including sterilization, filtration, and fermentation
Data Source
AI summary
A fiber reactor system includes a fiber slurry tank configured for receiving fiber feed containing cellulose and hemicellulose for forming a fiber slurry, which is mixed with evaporator condensate. The fiber slurry is mixed with steam vapors for sterilizing. A fiber reactor system is configured for receiving ruled fiber and mixing with microorganisms. The scrubber water is fed the top of a scrubber to capture ethanol and an ethanol-laden fiber stream is sent to a low-ethanol beer stripping system.