Single Vessel Free Fall Mixing for High Dry Matter Waste
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Solution Overview
Problem
Current bioethanol production processes face challenges in efficiently handling waste fractions with high dry matter content and large particles, requiring costly sorting and grinding, and often involve pressurized conditions that increase energy and equipment costs, as well as environmental concerns from incineration.
Innovation Solution
A process that integrates non-pressurized pre-treatment, enzymatic hydrolysis, and fermentation in a single vessel using a free fall mixing principle, eliminating the need for sorting and grinding, and allowing for efficient treatment of high dry matter content waste fractions with large particles, without additional water or mechanical shredding, and enabling ethanol recovery in the same vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sorting and grinding systems are used for waste fractions, then the waste can be processed into organic slurry, but the device complexity and cost increase significantly
Solution Approach 1:
The patent combines pre-treatment, hydrolysis, and fermentation steps into a single vessel, eliminating the need for separate sorting and grinding systems. The free fall mixing principle enables direct processing of heterogeneous waste fractions without mechanical size reduction, thereby reducing device complexity while maintaining manufacturing ease.
Solution Approach 2:
The single vessel is designed to perform multiple functions: pre-treatment of waste fractions, enzymatic hydrolysis of polysaccharides, and fermentation of sugars. This multi-functional approach eliminates the need for dedicated equipment for each step, reducing overall system complexity and cost.
2Productivity
If pressurized pre-treatment is used to break down plant materials, then hydrolysis efficiency improves, but energy consumption and equipment costs increase
Solution Approach 1:
The patent changes the pressure parameter from high (conventional pressurized systems) to atmospheric pressure. The free fall mixing mechanism provides sufficient mechanical action for enzyme-substrate contact without requiring pressurization, thereby maintaining hydrolysis efficiency while dramatically reducing energy consumption.
Solution Approach 2:
The patent replaces the mechanical pressurization system with a free fall mixing system. Instead of using pressure to achieve substrate penetration and enzyme contact, the system uses gravitational free fall of mixing elements, eliminating the need for high-pressure equipment and associated energy costs.
3Loss of energy
If incineration is used for waste treatment, then energy recovery is achieved, but environmental pollution and loss of valuable materials occur
Solution Approach 1:
The patent recovers valuable fermentation products (ethanol, organic acids, gases) from waste fractions instead of destroying them through incineration. The process converts organic matter into useful biochemical products, eliminating harmful emissions while preserving and recovering energy and material value.
Solution Approach 2:
The patent converts what would be harmful waste material requiring incineration into valuable fermentation products. By using enzymatic hydrolysis and fermentation, the process transforms organic waste into ethanol and other useful compounds, turning a potential environmental hazard into a beneficial resource.
4Ease of operation
If additional water and mechanical shredding are applied to high dry matter waste, then processing becomes easier, but energy input and operational complexity increase
Solution Approach 1:
The free fall mixing system uses the weight of the mixing elements themselves to provide mechanical action, eliminating the need for external energy input for shredding. The system serves itself by using gravitational force to drive the mixing and size-reduction function, maintaining ease of operation without additional energy consumption.
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 process achieves enzymatic hydrolysis of over 50% of cellulose, hemicellulose, and starch into fermentable sugars and produces ethanol with a content above 4 vol.%, reducing energy input and costs while minimizing environmental impact.
Implementation Method 1
The mixing performed in this single vessel is based on a free fall mixing principle
Implementation Method 2
enzymatic hydrolysis of over 50% of cellulose, hemicellulose, and starch into fermentable sugars
Implementation Method 3
fermentation of waste fractions containing mono- and/or polysaccharides
Data Source
AI summary
The present invention relates to a process for production of fermentation products, including bioethanol by non-pressurized pre-treatment, enzymatic hydrolysis and fermentation of waste fractions containing mono- and/or polysaccharides, having a relatively high dry matter content. The process in its entirety, i.e. from non-pressurized pre-treatment over enzymatic hydrolysis and fermentation to sorting of fermentable and non-fermentable solids can be processed at a relatively high dry matter content in a single vessel or similar device using free fall mixing for the mechanical processing of the waste fraction.