Direct Granulation of Lysine Fermentation Broth
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Solution Overview
Problem
Traditional lysine production methods face issues such as high costs, environmental pollution, and inconsistent product quality due to the use of ion-exchange resins and complex filtering processes, and the resulting powder form is hazardous and inefficient.
Innovation Solution
A method involving direct granulation of a lysine fermentation broth without filtering, using a fluidized bed granulator to coat and dry particles, resulting in a product with a dense onion-like structure and controlled particle size distribution, which reduces hygroscopicity and increases lysine content without the need for anti-hygroscopic substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional filtering and ion-exchange processes are used to produce lysine powder, then product purity is improved, but production cost increases and environmental pollution occurs
Solution Approach 1:
The invention extracts and removes the harmful and costly filtering and ion-exchange processes from the traditional lysine production method. By directly granulating the fermentation broth without these intermediate steps, the process eliminates expensive filters and ion-exchange resins while reducing wastewater generation, thus lowering production costs and environmental impact while maintaining product quality through the granulation process itself
Solution Approach 2:
The invention changes the physical state and form of the product from powder to granules through direct granulation of the fermentation broth. This parameter change in product form eliminates the need for traditional purification processes, as the granulation process itself achieves the necessary separation and concentration, thereby reducing production costs and environmental pollution while maintaining adequate product purity
2Reliability
If traditional filtering processes are used to remove micro-organisms, then product safety is improved, but yield decreases and protein content reduces
Solution Approach 1:
The invention removes the filtering step that eliminates micro-organisms from the process, but compensates by using direct granulation which naturally separates and concentrates the lysine while retaining biomass. This extraction of the harmful filtering process prevents yield loss and protein content reduction while maintaining product safety through the granulation mechanism
Solution Approach 2:
The invention merges the concentration and separation functions into the single granulation process. Instead of separately filtering to remove micro-organisms and then concentrating the lysine, the granulation process simultaneously achieves both objectives by forming granules that contain the lysine while the process conditions control the inclusion of biomass, thereby maintaining yield and protein content
3Productivity
If ion-exchange resins are used to concentrate L-lysine, then concentration efficiency is improved, but cost price increases and wastewater pollution occurs
Solution Approach 1:
The invention extracts and eliminates the ion-exchange resin step from the concentration process. By using direct granulation of the fermentation broth, the process achieves concentration without requiring ion-exchange resins, thereby eliminating the source of enormous wastewater generation and associated pollution while maintaining concentration efficiency through the granulation mechanism
Solution Approach 2:
The invention converts the potentially harmful fermentation broth, which contains micro-organisms and impurities, directly into the beneficial granulated product. By granulating the broth without prior filtering or ion-exchange treatment, the process turns what would be waste streams into valuable product components, eliminating wastewater pollution while achieving concentration
4Manufacturing precision
If lysine is produced in powder form, then product purity is improved, but handling safety deteriorates and storage becomes difficult
Solution Approach 1:
The invention changes the physical form parameter of the product from powder to granules through direct granulation of the fermentation broth. This parameter change improves handling safety by reducing dust generation and improving flow properties, while also improving storage characteristics by reducing hygroscopicity, all while maintaining adequate product purity through the granulation 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
This method simplifies the production process, reduces costs, and achieves a consistent lysine content within 1% of the target, while minimizing hygroscopicity and environmental impact by eliminating the need for expensive filters and ion-exchange resins.
Implementation Method 1
blowing air in the chamber upward from under the particles such that a least part of the particles float within the chamber
Implementation Method 2
spraying a liquid composition comprising L-lysine in the chamber while blowing air in the chamber, wherein the liquid composition is coated over individual particles floating within the chamber
Implementation Method 3
the liquid composition coated over the particles is dried by the air blown in the chamber
Data Source
AI summary
A process for the production of animal feed additives from fermentation broth containing L-lysine is disclosed. The process does not require filtering of biomass in order to remove the biomass and produces granulated lysine of controllable lysine content with a high bulk density, low viscosity, and a low hygroscopic property which does not require the addition of an anti-absorptive substance. In this process, a lysine fermentation broth produced after slant culture, flask culture, seed process, and cultivation process is concentrated to a solid content of about 44˜52%. A product with low hygroscopicity, high bulk density, and the intended amount of contents is produced after being mixed with substances for controlling the amount of contents and granulated by coating the surface of the seeds. This process enables a production of animal feed additives having a lysine-HCl content of at least 65%, a water content of at most 3%, and a bulk density of 670±50 kg/m3.