Gas-fed Fermenter Design for Methane Conversion Mass Transfer
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Solution Overview
Problem
Current methods for converting methane and similar carbon-containing gases to higher value hydrocarbons are hindered by low yields, poor selectivity, and high capital costs, particularly due to the Fischer-Tropsch process, which limits the scalability and efficiency of gas-to-liquids production, leading to stranded gas deposits being vented or flared.
Innovation Solution
A fermentation system utilizing C1 metabolizing non-photosynthetic microorganisms, such as methanotrophs and methylotrophs, to efficiently convert gaseous substrates like methane into higher hydrocarbons, with a scalable fermentor design that enhances gas-phase to liquid-phase mass transfer and waste gas removal, allowing for the production of gaseous and liquid hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the Fischer-Tropsch process is used to convert methane to higher-order hydrocarbons, then large quantities of methane can be processed, but the process suffers from low yields, poor selectivity, and requires massive capital expenditure and scale
Solution Approach 1:
The patent replaces the complex chemical catalysis system of Fischer-Tropsch with a biological fermentation system using engineered microorganisms. The mechanical/chemical process of syngas conversion is substituted with biological metabolism, where microorganisms naturally convert C1 substrates to hydrocarbons with higher selectivity and yield, eliminating the need for massive capital infrastructure while improving product precision
Solution Approach 2:
The invention changes the fundamental conversion parameters by using biological systems that operate under milder conditions with different kinetic profiles. The engineered microorganisms exhibit optimized metabolic pathways that achieve superior carbon efficiency and hydrocarbon selectivity compared to the high-temperature, high-pressure Fischer-Tropsch conditions, thereby improving manufacturing precision without requiring massive scale
2Ease of manufacture
If the Fischer-Tropsch process is used, then methane can be converted to liquid products, but the process requires significant capital expenditure and large scale to achieve economical production
Solution Approach 1:
The patent substitutes the complex mechanical and chemical infrastructure of Fischer-Tropsch plants with a biological fermentation system. The engineered microorganisms perform the gas-to-liquid conversion through metabolic processes, eliminating the need for expensive syngas generation equipment, high-temperature reactors, and complex catalyst systems, thereby dramatically reducing capital expenditure and plant scale requirements
Solution Approach 2:
The invention uses simple, scalable fermentation vessels and engineered microorganisms that can be rapidly deployed and scaled. Unlike the permanent, expensive Fischer-Tropsch infrastructure, the biological system uses consumable biological catalysts (microorganisms) that can be continuously cultured and replaced, enabling flexible, low-capital entry and scaling without massive plant construction
3Productivity
If conventional fermentation systems are used for gaseous substrates, then gas conversion can occur, but mass transfer from gas phase to liquid phase is inefficient
Solution Approach 1:
The patent introduces a two-phase fermentation system with a gas phase and a liquid phase, adding a dimensional aspect to mass transfer. The system uses gas sparging and liquid recirculation to create intense gas-liquid contact, effectively utilizing the third dimension (vertical gas flow) to enhance mass transfer surface area and efficiency, thereby improving both productivity and mass transfer quantity
Solution Approach 2:
The invention employs porous spargers and distributed gas injection systems that create fine gas bubbles with high surface area to volume ratio. These porous structures enhance the gas-liquid interfacial area dramatically, improving mass transfer efficiency and enabling higher gas conversion rates by maximizing the quantity of substrate available for microbial uptake
4Ease of operation
If methane is converted to liquid products for easier transport, then transportation becomes feasible, but existing methods have low yields and poor selectivity
Solution Approach 1:
The patent replaces the low-selectivity Fischer-Tropsch chemical synthesis with a biological system that naturally produces hydrocarbons with higher selectivity. The engineered microorganisms channel carbon flow preferentially to desired hydrocarbon products, achieving superior manufacturing precision while still producing liquid or gaseous fuels that are easy to transport and handle
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 the efficient conversion of methane and other gaseous substrates into higher value hydrocarbons, overcoming the limitations of existing technologies by improving mass transfer and scalability, thus providing a more economical and environmentally friendly solution for utilizing stranded gas deposits.
Implementation Method 1
A fermentation system utilizing C1 metabolizing non-photosynthetic microorganisms, such as methanotrophs and methylotrophs, to efficiently convert gaseous substrates like methane into higher hydrocarbons
Implementation Method 2
a scalable fermentor design that enhances gas-phase to liquid-phase mass transfer
Data Source
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AI summary
A fermenter can have at least one hollow fluid conduit disposed at least partially within a vessel. An external circumference of the hollow fluid conduit and an interior circumference of the vessel can define a downward flow path through which a multi-phase mixture including a liquid media and compressed gas substrate bubbles flows. An interior circumference of the hollow fluid conduit can defined an upward flow path which is in fluid communication with the downward flow path. The multi-phase liquid can flow through the upward flow path and exit the fermenter. Cooling may be provided in the hollow fluid conduit or the vessel. One or more backpressor generators can be used to maintain a backpressure on the fermenter. One or more fluid movers can be used to variously create an induced and/or forced flow in the downward and upward flow paths.