Hydraulic Gas Injector for Fermentation Vessels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial-scale production of liquid products from syngas in deep fermentation vessels requires efficient gas dispersion without the need for large compressors, as existing methods are energy-intensive and prone to compressor damage from residual materials in the syngas.
Innovation Solution
The process involves injecting a feed gas stream into a deep fermentation vessel using the fermentation liquid as a motive liquid to create a stable gas-liquid dispersion at a high elevation, eliminating the need for compressors by utilizing the liquid's surface tension-reducing properties and hydraulic head to maintain dispersion over long distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas compression is used to create fine dispersion, then gas dispersion quality is improved, but energy consumption increases
Solution Approach 1:
The patent replaces the mechanical compression system with a hydraulic injection system. Gas is injected into the liquid phase using liquid pressure rather than mechanical compressors, thereby achieving fine gas dispersion while avoiding the high energy consumption associated with mechanical compression. The liquid stream provides the driving force for gas dispersion through hydraulic means.
Solution Approach 2:
The patent employs hydraulic injection to disperse gas into liquid. A liquid stream is used to inject and disperse gas bubbles throughout the fermentation broth, utilizing hydraulic pressure and flow to achieve fine dispersion without requiring mechanical gas compression. This hydraulic approach consumes less energy while maintaining effective gas-liquid contact.
2Stress or pressure
If compressors are used for gas injection, then gas pressure is improved, but system reliability deteriorates due to residual materials damage
Solution Approach 1:
The patent substitutes mechanical compressors with a hydraulic injection system that uses liquid pressure to inject gas into the fermentation vessel. This eliminates the reliability issues associated with compressors encountering residual materials in syngas, such as particulates and tars, which can cause damage and downtime. The liquid-driven injection system has no moving parts susceptible to such damage.
Solution Approach 2:
The patent introduces liquid as an intermediary medium to transfer energy and pressure to the gas phase. Instead of directly compressing gas with mechanical devices that are vulnerable to damage, the liquid stream serves as a mediator that carries the gas into the fermentation broth under pressure, protecting the system from the harmful effects of residual materials.
3Manufacturing precision
If gas is injected at high pressure, then gas dispersion is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical compression and pressure control systems with a simpler hydraulic injection system. The liquid circulation system, already present in the fermentation process, is used to provide the pressure and flow needed for gas dispersion. This substitution reduces device complexity while maintaining effective gas-liquid mixing.
Solution Approach 2:
The patent makes the liquid circulation system serve multiple functions: it circulates fermentation broth for process purposes and simultaneously acts as the driving force for gas injection and dispersion. This multi-functionality eliminates the need for separate gas compression and injection equipment, thereby reducing overall device complexity.
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 reduces energy input, prevents bubble coalescence, and enhances gas transfer efficiency, allowing for effective conversion of CO and H2 to liquid products like ethanol without the need for compressor-driven high-pressure gas injection.
Implementation Method 1
The gas injector mixes the feed gas stream with the working fluid using the pumping of the working fluid as the primary energy input to create a gas-liquid dispersion
Implementation Method 2
utilizing the liquid's surface tension-reducing properties and hydraulic head to maintain dispersion over long distances
Implementation Method 3
utilizing the liquid's surface tension-reducing properties and hydraulic head to maintain dispersion over long distances
Data Source
AI summary
A process for conversion of syngas to liquid products that serve as surface acting agents uses the gas stream at a relatively low pressure to eliminate the use of a compressor. The process uses a liquid stream as the primary energy input to a gas injector that intensely mixes gas and the liquid with reduced compression costs while the presence of the liquid product maintains the gas-liquid dispersion as it flows downward to build a static pressure head. The process lowers the required gas pressure by adjusting the elevation of the gas injector such that a conduit receives the gas-liquid dispersion from the outlet of the injector and confines it as it travels downward to enter the bottom of a column of liquid. The liquid product provides a surface acting agent that prolongs the creation and duration of microbubbles in the gas-liquid dispersion.