Online Image Analysis for Sugar Production Process Control

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Solution Overview

Problem

Current methods for controlling the pretreatment of lignocellulosic biomass for sugar production are inefficient due to the need for time-consuming manual sampling and laboratory analysis, which are unsuitable for continuous processes with varying feedstock properties, leading to challenges in maintaining optimal enzymatic availability and preventing sugar degradation and inhibitor production.

Innovation Solution

Implementing an online image analysis method to monitor enzymatic availability of pretreated biomass, using image processing to capture and analyze visual characteristics of cellulosic particles, allowing for real-time feedback and feed-forward control of the pretreatment and enzymatic hydrolysis processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual sampling and laboratory analysis methods are used to monitor pretreatment process, then measurement accuracy can be maintained, but the analysis time is too long for continuous process control

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidanalysis time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical sampling and laboratory analysis with an automated optical imaging system. The image capturing device takes pictures of the slurry, and image processing automatically analyzes particle characteristics, eliminating the need for manual intervention and significantly reducing analysis time while maintaining measurement accuracy through systematic image analysis algorithms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates visual copies (images) of the slurry particles and analyzes these copies instead of physically handling and chemically analyzing the actual samples. This allows for rapid, non-destructive measurement that can be performed continuously without the time-consuming laboratory procedures, while the image data accurately represents the physical properties of the particles.

Inventive Principle:

Principle #26Copying

2Productivity

If pretreatment severity is increased to improve enzymatic availability, then enzymatic hydrolysis efficiency improves, but sugar degradation and inhibitor production increase

Engineering Contradiction:

Improveenzymatic hydrolysis efficiencyVSAvoidsugar degradation and inhibitor production

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent implements a feedback control system where image analysis of particle characteristics continuously monitors the pretreatment state. The system compares measured parameters (particle size, shape, texture) against target ranges and automatically adjusts pretreatment parameters to maintain optimal conditions, preventing both insufficient pretreatment (low enzymatic availability) and excessive pretreatment (sugar degradation and inhibitor formation).

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent makes the pretreatment process dynamic and adaptive by continuously adjusting process parameters based on real-time image analysis feedback. Instead of fixed pretreatment conditions, the system dynamically modulates severity parameters to match the actual feedstock characteristics and achieve optimal enzymatic availability while avoiding harmful side effects.

Inventive Principle:

Principle #15Dynamics

3Productivity

If continuous process with varying feedstock is used to improve productivity, then sugar production efficiency increases, but process control difficulty increases due to feedstock property variations

Engineering Contradiction:

Improvesugar production efficiencyVSAvoidprocess control difficulty

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent enables the process to self-adjust by using image analysis to automatically detect feedstock variations and trigger appropriate control actions. The system monitors particle characteristics in real-time and autonomously adjusts pretreatment parameters without requiring manual intervention or complex external control systems, simplifying the overall control architecture while handling feedstock variability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent performs preliminary characterization of feedstock through image analysis before the pretreatment process begins. By measuring particle size, shape, and texture of the incoming material, the system pre-determines appropriate pretreatment parameters tailored to that specific feedstock, enabling smooth continuous operation with varying materials while maintaining optimal process conditions.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9580763B2Image analysis based process control of processes for production of sugar from lignocellulosic biomass

Publication Date: 2017.02.28 SEKAB E TECHNOLOGY AB

AI summary

There is provided a method of producing a hydrolysate containing sugar from a lingocellulosic biomass, comprising the steps of: a) pretreating the lingocellulosic biomass in a pretreatment process to form a slurry comprising cellulosic particles; b) saccharification of the slurry obtained in step a) in the presence of hydrolytic enzymes in an enzymatic hydrolysis process to obtain a hydrolysate containing sugar; c) analyzing cellulosic particles present in the slurry obtained in step a) and/or cellulosic particles present in the enzymatic hydrolysis process during step b) using an image analysis method to obtain a data set; and d) controlling at least one process parameter of the pretreatment process in step a) and/or enzymatic hydrolysis process in step b) in response to the data set obtained in step c). A corresponding system is also provided.