In Situ Macrofiltration for High-Purity MEL Recovery
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Solution Overview
Problem
Existing methods for producing mannosylerythritol lipids (MELs) are inefficient, requiring multiple solvent extractions and long fermentation times, with high substrate consumption and low purity, especially due to the challenge of separating MELs from triacylglycerols and other lipidic impurities.
Innovation Solution
A macrofiltration device and system that allows for in situ recovery of MELs particles during fermentation, using a grid with specific channel widths to retain particles while recycling fermentation broth, combined with a process involving hydrolyzed or trans-esterified lipid substrates and solvent washing to enhance production efficiency and purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple liquid-liquid extractions using several organic solvents are used for MELs separation, then separation efficiency is improved, but device complexity and process time increase
Solution Approach 1:
The patent extracts MELs from fermentation broth using a single organic solvent (ethyl acetate or n-butanol) instead of multiple solvents. The extraction process involves mixing the fermentation broth with the organic solvent, allowing MELs to partition into the organic phase, followed by separation and concentration to obtain purified MELs product.
Solution Approach 2:
The patent segments the extraction process into distinct stages: (1) extraction with organic solvent, (2) phase separation, (3) concentration of organic phase, and (4) final purification. This segmentation allows each step to be optimized independently while maintaining overall efficiency.
2Manufacturing precision
If multiple liquid-liquid extractions using several organic solvents are used for MELs separation, then separation efficiency is improved, but fermentation time increases
Solution Approach 1:
The patent extracts MELs from fermentation broth using a single organic solvent (ethyl acetate or n-butanol) instead of multiple solvents. The extraction process involves mixing the fermentation broth with the organic solvent, allowing MELs to partition into the organic phase, followed by separation and concentration to obtain purified MELs product.
Solution Approach 2:
The patent performs preliminary concentration of the organic phase before final purification steps. This preliminary action reduces the volume of material requiring further processing, thereby reducing overall process time while maintaining separation efficiency.
3Productivity
If large amounts of vegetable oil are used as substrate, then MELs production titer is improved, but product purity deteriorates due to unconsumed oil contaminants
Solution Approach 1:
The patent extracts MELs from fermentation broth using a single organic solvent (ethyl acetate or n-butanol) instead of multiple solvents. The extraction process involves mixing the fermentation broth with the organic solvent, allowing MELs to partition into the organic phase, followed by separation and concentration to obtain purified MELs product.
Solution Approach 2:
The patent changes the physical-chemical parameters of the system by using organic solvents with specific solubility characteristics. The chosen solvents (ethyl acetate or n-butanol) have selective solubility for MELs versus triacylglycerols, allowing differentiation and separation based on these parameter differences.
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 system enables faster and more efficient MELs production with reduced solvent use, higher purity (up to 90%), and continuous fermentation without substrate loss, forming stable particles with improved physical characteristics.
Implementation Method 1
a device (1) for macrofiltration comprising a grid (20), the grid comprising a plurality of channels, each channel having a width between 0.3 mm and 10 mm; the grid separating a first chamber and a second chamber
Implementation Method 2
the at least one inlet (22) is configured to evenly supply a fluid to the first chamber
Implementation Method 3
the at least one outlet (24) is configured to connect the second chamber to a bioreactor (2)
Implementation Method 4
MELs production can last up to 240-336 hours. The more efficient method reported in the literature used for the separation of MELs from the fermentation broth
Data Source
AI summary
Device (1) and system for macrofiltration are disclosed. The macrofiltration comprises mannosylerythritol lipids (MELs) recovery, the MELs being in the form of particles. System comprising the device (1) is also disclosed. The system comprises a first pathway (6) in fluid communication, wherein this first pathway comprises sequentially a first valve (3), a first pump (4), a bioreactor (2) and a second valve (10), and where this first pathway is between the at least one outlet and inlet of the device (1). Process for enhancing mannosylerythritol lipids (MELs) production is also disclosed.