On-Farm High-Solids Biomass Processing System
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Solution Overview
Problem
Current methods for converting biomass into industrial chemicals are inefficient and require significant energy input, often involving sterilization and liquid fermentation systems, which are energy-intensive and not well-integrated with agricultural practices.
Innovation Solution
A consolidated on-farm biomass processing method that includes in-situ delignification using biomimetic or biological reactions, followed by cellulase production and simultaneous cellulolytic and solventogenic reactions, utilizing existing on-farm storage technology and anaerobic microorganisms, with online product removal and recycling of fermentation residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sterilization and liquid fermentation systems are used to convert biomass into industrial chemicals, then the conversion process can be performed, but significant energy input is required
Solution Approach 1:
The patent changes the physical state parameter from liquid fermentation to high-solids (semi-solid) fermentation, operating at 15-50% total solids content. This parameter change eliminates the need for sterilization while maintaining effective conversion, thereby reducing energy input significantly
Solution Approach 2:
The patent extracts and removes the sterilization step from the conventional liquid fermentation process. By using high-solids fermentation with controlled inoculation, the sterilization requirement is eliminated entirely, reducing energy consumption without compromising conversion reliability
2Productivity
If conventional biomass processing methods are used, then industrial chemicals can be produced, but the methods are not well-integrated with agricultural practices
Solution Approach 1:
The patent makes the biomass processing system multi-functional by integrating it with existing agricultural infrastructure. The system can process various agricultural residues (corn stover, wheat straw, rice hulls) and the residues can be returned to farms as fertilizers or feed, creating a circular system that serves both industrial chemical production and agricultural needs
Solution Approach 2:
The patent enables farms to serve themselves by processing their own biomass residues on-site. The system uses locally available agricultural waste as feedstock and returns processed residues to the same farm, creating a self-sufficient system that reduces transportation needs and integrates seamlessly with agricultural operations
3Use of energy by moving object
If high-solids fermentation is used to reduce energy input, then energy consumption decreases, but the process complexity increases
Solution Approach 1:
The patent applies preliminary delignification treatment to the biomass feedstock before fermentation. This pre-treatment simplifies the subsequent high-solids fermentation process by making the lignocellulosic material more accessible to enzymes, thereby reducing process complexity while maintaining low energy consumption
Solution Approach 2:
The patent implements continuous or semi-continuous fermentation processes where inoculum is added progressively and residues are removed continuously. This maintains optimal fermentation conditions throughout the process, simplifying control requirements while keeping energy consumption low
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 method reduces energy input, integrates efficiently with agricultural practices, and produces valuable industrial chemicals like ethanol and organic acids, while returning residues to the farm as fertilizers, enhancing profitability and rural job creation.
Implementation Method 1
That biomimetic reaction may be selected from a group consisting of Fenton chemistry, adding iron and peroxide to the biomass feedstock
Implementation Method 2
the cellulase is produced by contacting the biomass feedstock with an anaerobic microorganism
Implementation Method 3
subjecting the delignified biomass with attached cellulase to simultaneous cellulolytic and solventogenic reactions
Implementation Method 4
simultaneous cellulolytic and solventogenic reactions to produce a fermentation broth including useful industrial chemicals
Data Source
AI summary
A method for on-farm processing a biomass feedstock into a useful industrial chemicals includes the steps of (a) delignifying the biomass feedstock to produce a delignified biomass, (b) subjecting the delignified biomass to cellulase production, (c) subjecting the delignified biomass with attached cellulase to simultaneous cellulolytic and solventogenic reactions to produce useful industrial chemicals (d) collecting and separating the useful industrial chemical from the fermentation broth and (e) collecting the fermentation residues.