Lactic Acid Fermentation With Hydrocyclone Silica Removal
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Solution Overview
Problem
Existing processes for large-scale production of lactic acid using calcium hydroxide-based pH control agents face issues with silica content in lime causing equipment damage and yield loss due to equipment failure or filtration problems.
Innovation Solution
A continuous process utilizing hydrocyclones to separate silica early in the production process, followed by centrifugation and acidulation, to produce high-purity lactic acid while minimizing equipment damage and increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If calcium hydroxide-based pH control agents are used in fermentation, then pH control effectiveness is improved, but silica content causes equipment damage and yield loss
Solution Approach 1:
The patent applies preliminary action by removing silica from the calcium hydroxide-based pH control agent before it enters the fermentation process. A hydrocyclone is used to separate silica particles from the pH control agent slurry, ensuring that only the beneficial calcium hydroxide components proceed to pH regulation while the harmful silica is eliminated beforehand.
Solution Approach 2:
The patent applies the extraction principle by specifically removing silica particles from the calcium hydroxide-based pH control agent using a hydrocyclone separator. This separation extracts the harmful silica component while retaining the useful pH control properties of calcium hydroxide, preventing equipment damage and yield loss downstream.
2Manufacturing precision
If traditional filtration methods are used after acidulation, then lactic acid purification is achieved, but filter aid consumption increases and equipment damage occurs
Solution Approach 1:
The patent applies preliminary action by removing silica early in the process before acidulation occurs. By using a hydrocyclone to separate silica from the pH control agent beforehand, the patent prevents silica from interfering with subsequent filtration operations, thereby reducing filter aid consumption and avoiding equipment damage that would otherwise be necessary to handle silica-contaminated streams.
3Device complexity
If silica is not removed early in the process, then process simplicity is maintained, but equipment damage and production efficiency decrease
Solution Approach 1:
The patent introduces a hydrocyclone separation step early in the process to remove silica from the calcium hydroxide-based pH control agent before fermentation. This preliminary removal action prevents downstream equipment damage and maintains high production rates, demonstrating that a simple additional separation step can effectively protect productivity without significantly complicating the overall process.
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
The process effectively removes silica before acidulation, preventing equipment damage and increasing production rates, allowing for efficient large-scale lactic acid recovery with reduced filter aid consumption and improved gypsum separation.
Implementation Method 1
A continuous process utilizing hydrocyclones to separate silica early in the process
Implementation Method 2
followed by centrifugation and acidulation
Data Source
AI summary
Lactic acid is prepared by fermenting a carbohydrate source in the presence of a calcium hydroxide-based pH control agent that comprises from about 0.1 to about 10 wt % silica to form a fermentation broth comprising lactic acid and calcium lactate. The fermentation broth is processed by a sequence of hydrocyclones to remove silica from the feed streams to avoid fouling of equipment and to avoid damage to filtration or centrifugation equipment. The biomass component of the fermentation broth is separated out prior to acidulation of the fermentation broth, and therefore itself is a viable product for use since it can be provided without filter aid components that were previously required when the biomass was removed during acidulation. Gypsum is recovered after the acidulation step, and can be available as a product by itself, or combined with the biomass as a mixed product.