Integrated Gas Fermentation Process for Waste Valorization
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Solution Overview
Problem
Current gas fermentation processes face challenges in maximizing the value of materials, as byproducts from feedstock preparation are often discarded rather than being recycled and utilized downstream.
Innovation Solution
An integrated process that combines feedstock preparation through partial oxidation, pyrolysis, torrefaction, reforming, or gasification with gas fermentation, where the produced syngas and byproducts are passed to a bioreactor containing a C1-fixing microorganism to produce fermentation products, which are then jointly provided to a downstream operation to produce an article of manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If byproducts from feedstock preparation are discarded, then the process is simpler and costs are lower, but material value is lost and waste increases
Solution Approach 1:
The patent merges the feedstock preparation process with gas fermentation by integrating the byproduct stream into the fermentation process. The byproducts from feedstock preparation (such as CO2, CO, and other gases) are combined with the main syngas stream and fed to the bioreactor, creating a unified process that recycles valuable materials rather than discarding them separately.
Solution Approach 2:
The patent recovers byproducts from feedstock preparation that would otherwise be discarded. The system captures gases like CO2 and CO generated during feedstock preparation and redirects them to the gas fermentation process, recovering their material value and reducing waste. This is achieved by implementing a byproduct recovery stream that feeds back into the fermentation process.
2Productivity
If byproducts are recycled to downstream operations, then material value increases and waste reduces, but process complexity increases
Solution Approach 1:
The patent creates a multi-functional process where the same byproduct stream serves multiple purposes: it is used as a carbon source for gas fermentation, provides materials for downstream product synthesis, and reduces waste. The integrated system allows the byproduct stream to fulfill multiple functions simultaneously, increasing overall process value without requiring separate dedicated handling systems for each byproduct.
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 integrated approach enhances the recycling of valuable materials, increases the overall value of the process, and reduces waste by utilizing byproducts in downstream operations, thereby creating a more efficient and sustainable production cycle.
Implementation Method 1
Gas fermentation involves a gas stream of carbon monoxide, carbon dioxide, and or hydrogen provided to a bioreactor housing a microorganism biocatalyst
Implementation Method 2
The feedstock preparation process, which is processing to provide syngas, involves partial oxidation, torrefaction, reforming, pyrolysis or gasification
Implementation Method 3
The feedstock preparation process, which is processing to provide syngas, involves partial oxidation, torrefaction, reforming, pyrolysis or gasification
Data Source
AI summary
Integrated process for providing multiple raw materials to a downstream operation to generate an article of manufacture. Pyrolysis, torrefaction, reforming, partial oxidation, and/or gasification is integrated with gas fermentation. Integrated process converts carbon sources that would otherwise be vented to the atmosphere or discarded as waste to a fermentation product and one or more byproducts, which in turn are provided to a downstream operation to generate an article of manufacture. In certain aspects, the fermentation product may be ethanol, isoprene, butane diol, ethylene. In certain aspects, the byproduct may be metal, metal oxide, char, silica, and or steel. The downstream operation to generate an article of manufacture may be an operation to generate plastic products, rubber products, textiles, clothes, and the like.