Single Cell Protein Production via Loop Reactor and Synthetic Gas
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Solution Overview
Problem
Existing processes for producing single cell protein (SCP) are limited by dependence on natural gas availability, fluctuating fossil fuel costs, environmental impact, and complexity.
Innovation Solution
A process using a Loop reactor system where gaseous hydrogen and a carbon source are added to an inoculated fermentation medium, allowing fermentation to produce SCP independently of natural gas locations, with reduced environmental impact and increased simplicity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional methanotrophic microorganisms are used to digest natural gas, then SCP production is achieved, but the process location is limited to areas where natural gas is available and transportation costs increase
Solution Approach 1:
The patent extracts the carbon source requirement from natural gas dependency by introducing synthetic gas (synthesis gas) as an alternative carbon source. This allows the fermentation process to be conducted anywhere synthetic gas is available, eliminating the need to be located near natural gas fields or incur transportation costs for natural gas delivery.
Solution Approach 2:
The patent changes the carbon source parameter from natural gas (methane) to synthetic gas (a mixture containing carbon monoxide, carbon dioxide, hydrogen, and hydrogen sulfide). This parameter change enables location independence while maintaining SCP production capability through the use of microorganisms adapted to synthetic gas fermentation.
2Adaptability or versatility
If natural gas is transported to the SCP fermenter, then SCP production can occur away from natural gas fields, but additional transportation costs are added to production
Solution Approach 1:
The patent extracts the dependency on natural gas transportation by using synthetic gas as the carbon source. Synthetic gas can be produced locally from various feedstocks (coal, gasification products, etc.), eliminating the need to transport natural gas over long distances and reducing transportation costs in the production process.
3Productivity
If methanogenic microorganisms are used, then SCP production is achieved, but the process is affected by fluctuating fossil fuel costs
Solution Approach 1:
The patent changes the carbon source from fossil fuel-based natural gas to synthetic gas that can be produced from alternative feedstocks. This parameter change reduces exposure to fluctuating fossil fuel prices while maintaining SCP production capability, as synthetic gas can be generated from coal, gasification products, or other non-fossil fuel sources.
4Productivity
If natural gas is used as carbon source, then SCP production is achieved, but environmental and atmospheric harm is caused
Solution Approach 1:
The patent converts the potentially harmful synthetic gas (which may contain harmful components like hydrogen sulfide) into a beneficial carbon source for SCP production. The microorganisms utilize the synthetic gas to produce biomass, thereby converting what could be considered a harmful substance into a useful resource for protein production, while also reducing dependence on fossil fuel extraction.
5Reliability
If co-fermentation of different microorganisms is used to digest natural gas components, then complete digestion is achieved, but process complexity and reliability decrease
Solution Approach 1:
The patent extracts the need for complex co-fermentation by using microorganisms that are specifically adapted to synthetic gas fermentation. These microorganisms can utilize the synthetic gas components (carbon monoxide, carbon dioxide, hydrogen) more efficiently and reliably than mixed microorganism communities, simplifying the fermentation process while maintaining effectiveness.
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 process enables SCP production that is independent of natural gas locations, reduces environmental impact, and enhances productivity and efficiency, addressing the limitations of existing SCP production methods.
Implementation Method 1
adding gaseous hydrogen (H2) to the first inoculated fermentation medium; adding a first gaseous carbon source, such as a gaseous carbon monoxide (CO); a gaseous carbon dioxide (CO2) or a combination hereof, to the first inoculated fermentation medium or adding a non-gaseous carbon source... allowing the first fermentation medium to ferment, providing the first reaction product
Data Source
AI summary
Disclosed is a process method for producing a single cell protein comprising the steps of (a) providing gaseous hydrogen (H2); (b) mixing the hydrogen gas from step (a) with a carbon source, to provide a C1 compound, such as methane, methanol, formaldehyde, formic acid, methanethiol, or methanesulfonic acid, or derivates thereof; (c) adding or passing the C1 compound provided in step (b) to a loop reactor comprising one or more microorganisms capable of metabolizing the C1-compound providing an inoculated fermentation medium; (d) allowing the inoculated fermentation medium to ferment, in a fermentation process, and converting the C1 compound into a biomass material; and (e) isolating the biomass material provided in step (c) and providing the second single cell protein, wherein the carbon source is gaseous carbon monooxide (CO); gaseous carbon dioxide (CO2); or a combination hereof, or wherein the first carbon source is an aqueous solution of carbon dioxide, such as carbonic acid or a hydrogencarbonate or carbonate ion, or a combination thereof.