Loop Reactor Non-Vertical Pressure Reduction Zones
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Solution Overview
Problem
Current methods for converting methane to higher-value hydrocarbons are inefficient and costly due to the limitations of the Fischer-Tropsch process, which requires large-scale operations and is sensitive to contaminants, making it unsuitable for small-scale methane sources, and fermentation of gaseous substrates faces challenges in mass transfer and heat management.
Innovation Solution
The development of a loop reactor system with a gas/liquid separation vessel and non-vertical pressure reduction zones to enhance mass transfer of gaseous substrates to microbial cultures, allowing for efficient fermentation of methane and other carbon-containing gases, and the use of specific microorganisms like methanotrophs and methylotrophs to convert these gases into higher-value products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the Fischer-Tropsch process is used to convert methane to higher hydrocarbons, then large-scale production is achieved, but the process requires massive capital expenditure and is sensitive to contaminants
Solution Approach 1:
The patent divides the fermentation system into multiple photobioreactor modules that can be operated independently. Each module contains specific microbial communities (cyanobacteria, microalgae, bacteria) that perform different functions in the conversion process, allowing the system to handle small-scale methane sources efficiently without requiring massive capital investment
Solution Approach 2:
The patent changes the operating parameters from the high-temperature, high-pressure conditions required by Fischer-Tropsch to ambient or moderate conditions suitable for microbial fermentation. This includes operating at lower temperatures (20-40°C), atmospheric or near-atmospheric pressures, and pH ranges of 6-8, which reduces capital expenditure and makes the process less sensitive to contaminants
2Productivity
If gaseous substrates are fermented to produce higher hydrocarbons, then mass transfer efficiency is improved, but heat management becomes challenging
Solution Approach 1:
The patent transitions from traditional horizontal or vertical stirred-tank reactors to vertically stacked photobioreactor modules with integrated gas-liquid-solid separation zones. This dimensional reconfiguration allows simultaneous optimization of gas-liquid mass transfer at the bottom zones and heat dissipation through the vertical structure, with cooling systems integrated into the reactor walls
Solution Approach 2:
The patent introduces a liquid culture medium as an intermediary between the gaseous methane substrate and the microbial cells. This liquid phase facilitates efficient mass transfer of methane to the microbes while also serving as a heat transfer medium that can be circulated through cooling systems to manage the exothermic fermentation reactions
3Adaptability or versatility
If small-scale methane sources are utilized, then accessibility to stranded gas is improved, but the Fischer-Tropsch process becomes economically unviable
Solution Approach 1:
The patent creates a dynamic, scalable fermentation system that can adapt to varying methane feed rates and compositions typical of small-scale sources like landfills and sewage treatment facilities. The modular photobioreactor design allows the system to be sized and configured according to the specific characteristics of each methane source, maintaining economic viability across different scales
Solution Approach 2:
The patent changes the economic parameters by using low-cost microbial cultures that can be grown in simple liquid media, eliminating the need for expensive catalysts and high-capital infrastructure required by Fischer-Tropsch. The process operates at ambient conditions, reducing energy costs and equipment investment, making small-scale methane utilization economically feasible
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 enables efficient and scalable conversion of methane and other gaseous substrates into higher-value hydrocarbons and proteins, overcoming the limitations of existing technologies by improving mass transfer and heat management, and providing a cost-effective solution for small-scale methane utilization.
Implementation Method 1
enhance mass transfer of gaseous substrates to microbial cultures
Implementation Method 2
mass transfer of gaseous substrates to microbial cultures
Implementation Method 3
a first pressure reduction zone including a first pressure reduction device... passing the multi-phase mixture through the first pressure reduction zone
Implementation Method 4
separating the multi-phase mixture of a gas and a liquid culture medium into a gas phase and a liquid phase
Implementation Method 5
improving mass transfer and heat management
Implementation Method 6
fermentation of gaseous substrates faces challenges... use of specific microorganisms like methanotrophs and methylotrophs to convert these gases into higher-value products
Implementation Method 7
C1 metabolizing non-photosynthetic microorganism... convert these gases into higher-value products
Data Source
AI summary
Reactors, systems and processes for the production of biomass by culturing microorganisms in aqueous liquid culture medium circulating inner loop reactor which utilize nonvertical pressure reduction zones are described. Recovery and processing of the culture microorganisms to obtain products, such as proteins or hydrocarbons is described.