Natural Gas Bioreactor Control for Biomass Feed Instead of Flaring

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Natural gas produced during hydrocarbon production is often flared due to lack of accessible markets, contributing to greenhouse gas emissions and limited economic options for its utilization.

Innovation Solution

Convert natural gas into biomass using hydrocarbon-degrading microbes in a bioreactor, powered by a local power generator, with a dynamic control system balancing gas distribution to optimize electricity and heat production, and harvest the microbes as a protein feedstock.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If natural gas is flared at hydrocarbon production sites, then the gas is disposed of when markets are not accessible, but greenhouse gas emissions increase and economic value is lost

Engineering Contradiction:

Improveenergy loss from flaringVSAvoidgreenhouse gas emissions

Core Design Contradiction:

Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful act of flaring natural gas into a beneficial process by using the gas to power bioreactors that produce biomass. The natural gas that would otherwise be wasted and emit greenhouse gases is instead used as fuel to generate electricity and heat for microbial growth, transforming an environmental problem into an economic and environmental solution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system uses the natural gas produced at the hydrocarbon site to self-power the bioreactor operation. The gas fuels the power generator that provides electricity and heat to the bioreactor, creating a self-sustaining system where the waste product serves the production process without requiring external energy inputs.

Inventive Principle:

Principle #25Self-service

2Productivity

If natural gas is directed to a bioreactor for biomass production, then economic value is created and emissions are reduced, but energy and resources are consumed for bioreactor operation

Engineering Contradiction:

Improvebiomass production outputVSAvoidenergy consumption by bioreactor

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The bioreactor system is self-powered by the natural gas feedstock. The natural gas is combusted in a power generator that produces electricity and heat, which are then used to operate the bioreactor itself, eliminating the need for external energy inputs and making the system energy-self-sufficient.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent merges the energy generation function with the biomass production function by integrating the power generator and bioreactor into a single system. The natural gas serves dual purposes: as fuel for power generation and as substrate for microbial growth, combining two functions that would otherwise be separate.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If a dynamic control system is used to balance gas distribution between bioreactor and power generator, then operating costs are reduced and energy optimization is achieved, but system complexity increases

Engineering Contradiction:

Improveoperating cost optimizationVSAvoidcontrol system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The dynamic control system continuously monitors system parameters such as gas flow rates, power generation output, and bioreactor conditions, automatically adjusting the distribution of natural gas between the power generator and bioreactor to optimize performance and reduce operating costs based on real-time feedback.

Inventive Principle:

Principle #23Feedback

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

Provides an economically viable alternative to flaring, reducing greenhouse gas emissions and producing a valuable biomass protein source while optimizing energy use and reducing operating costs.

Implementation Method 1

directing a first fraction of the natural gas stream to a bioreactor comprising hydrocarbon degrading microbes

Methodology Applied

Scientific EffectBiological degradation: Decomposition (biological)

Implementation Method 2

converting the natural gas stream to electricity and heat

Methodology Applied

Scientific EffectMicrobial metabolism: Fermentation

Implementation Method 3

directing a second fraction of the stream to a local power generator and converting the natural gas stream to electricity and heat

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12565623B2Methods for biotechnological conversion of natural gas into animal feed as a substitute for flaring and related systems

Publication Date: 2026.03.03 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

Methods include providing a natural gas stream; directing a first fraction of the natural gas stream to a bioreactor including a propagating culture of hydrocarbon degrading microbes; directing a second fraction of the gas stream to a local power generator and converting the natural gas stream to electricity and heat; using a dynamic control system to balance of the gas stream to the first fraction and the second fraction based on one or more of the availability of electricity from an electricity grid and the price of electricity from the electricity grid; powering, at least in part, the bioreactor with the electricity generated by the local power generator; and harvesting the hydrocarbon degrading microbes from the bioreactor as a biomass. Related systems are also provided.