Gas Stream Purification via Sequential Removal Modules
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Solution Overview
Problem
Current systems fail to effectively clean gas streams for microbial gas fermentation, leading to excessive consumption of reactants, formation of undesired compounds, and insufficient reduction of inhibitory substances, which hampers the success of downstream fermentation processes.
Innovation Solution
A process involving a series of removal modules, including hydrolysis, acid gas removal, and deoxygenation, strategically positioned to remove constituents like carbonyl sulfide, hydrogen cyanide, and oxygen, producing a fermentable gas stream suitable for microbial fermentation without consuming desired compounds or forming inhibitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalytic conversion technologies are used to clean gas streams, then some impurities are removed, but excessive consumption of desired reactant compounds occurs and undesired compounds are formed
Solution Approach 1:
The gas cleaning process is divided into multiple sequential modules, each targeting specific impurity types: (1) particulate removal module for particles, (2) chloride removal module for HCl and ammonium chloride, (3) tar removal module for tars, (4) hydrolysis module for carbonyl sulfide and hydrogen cyanide, (5) acid gas removal module for acid gases, (6) deoxygenation module for oxygen and acetylene. This segmentation allows selective removal of impurities without excessive consumption of desired reactants like CO and CO2
Solution Approach 2:
The patent introduces specific intermediary substances and catalysts to facilitate selective impurity removal. For example, zinc oxide is used as an intermediary in the acid gas removal module to selectively bind acid gases, while copper-based catalysts in the deoxygenation module selectively remove oxygen and acetylene. These intermediaries enable targeted purification without affecting desired reactants
2Reliability
If conventional catalytic conversion technologies are used to clean gas streams, then some impurities are removed, but reaction to form other undesired compounds occurs which act as microbial inhibitors
Solution Approach 1:
The patent implements preliminary removal of specific impurities before they can react to form undesired compounds. The hydrolysis module converts carbonyl sulfide and hydrogen cyanide into removable forms before they can participate in unwanted reactions. The chloride removal module eliminates HCl and ammonium chloride early in the process, preventing their conversion into harmful byproducts that would inhibit microbial fermentation
Solution Approach 2:
The patent converts harmful impurities into beneficial or removable substances through controlled reactions. For example, the hydrolysis module converts toxic carbonyl sulfide and hydrogen cyanide into compounds that can be efficiently removed in subsequent modules. The deoxygenation module converts harmful oxygen and acetylene into harmless carbon dioxide and water, transforming inhibitors into non-inhibitory products
3Reliability
If conventional catalytic conversion technologies are used to clean gas streams, then some impurities are removed, but reduction of inhibitory compounds to sufficiently low levels is not achieved
Solution Approach 1:
The gas cleaning process is divided into multiple sequential modules, each targeting specific impurity types: (1) particulate removal module for particles, (2) chloride removal module for HCl and ammonium chloride, (3) tar removal module for tars, (4) hydrolysis module for carbonyl sulfide and hydrogen cyanide, (5) acid gas removal module for acid gases, (6) deoxygenation module for oxygen and acetylene. This segmentation allows selective removal of impurities without excessive consumption of desired reactants like CO and CO2
Solution Approach 2:
The system incorporates monitoring and control mechanisms to ensure inhibitory compounds are reduced to sufficiently low levels. The multi-module design with specific removal targets creates a feedback loop where each module's output is optimized for the next module's input, ensuring progressive reduction of inhibitors to levels suitable for microbial fermentation
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 effectively reduces inhibitory compounds to predetermined levels, ensuring successful noninhibited gas fermentation by efficiently removing harmful constituents from the gas stream, thereby enhancing the productivity and efficiency of microbial fermentation.
Implementation Method 1
passing the input gas stream to a hydrolysis module, wherein at least one constituent of the gas stream is removed and/or converted
Implementation Method 2
passing the post-hydrolysis gas stream to an acid gas removal module, wherein at least one further constituent of the gas stream is removed and/or converted
Data Source
AI summary
The invention provides a process for producing a fermentable gas stream from a gas source that contains one or more constituent which may be harmful to the fermentation process. To produce the fermentable gas stream, the gas stream is passed through a specifically ordered series of removal modules. The removal modules remove and/or convert various constituents found in the gas stream which may have harmful effects on downstream removal modules and/or inhibitory effects on downstream gas fermenting microorganisms. At least a portion of the fermentable gas stream is preferably capable of being passed to a bioreactor, which contains gas fermenting microorganisms, without inhibiting the fermentation process.