Bio-based Malonic Acid Purification via Calcium Precipitation

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Solution Overview

Problem

Current methods for producing malonic acid from petroleum-derived sources are low-yielding, environmentally damaging, and reliant on non-renewable feedstocks, with challenges in extracting and purifying bio-based malonate from biological fermentation.

Innovation Solution

The development of methods involving fermentation of microorganisms like Pichia kudriavzevii in the presence of a fermentable carbon source and an alkaline earth metal base, using seed crystals to form insoluble alkaline earth metal malonate salts, followed by extraction, conversion to soluble malonic acid, and crystallization, to produce high-purity bio-based malonic acid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If petroleum-derived feedstocks are used for malonic acid production, then production yield is improved, but environmental damage and reliance on non-renewable resources worsen

Engineering Contradiction:

Improveproduction yieldVSAvoidenvironmental damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the fundamental parameter of feedstock source from petroleum-derived to renewable biological sources (glucose, sucrose, molasses, agricultural waste). This parameter change enables sustainable malonic acid production while maintaining commercial viability through optimized fermentation conditions and downstream processing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses inexpensive, readily available renewable feedstocks such as glucose, sucrose, molasses, and agricultural waste products. These short-living, disposable feedstocks are converted into valuable malonic acid through fermentation, creating an economically sustainable production model that eliminates dependence on depleting petroleum resources

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Device complexity

If conventional extraction methods are used for bio-based malonate, then process simplicity is maintained, but purification efficiency and product purity worsen

Engineering Contradiction:

Improveprocess simplicityVSAvoidproduct purity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The invention segments the purification process into distinct stages: (1) cell separation to remove biomass, (2) malonate extraction using organic solvents or adsorbents, (3) solvent removal or desorbate recovery, and (4) final product isolation. This segmentation enables high purity product while maintaining reasonable process complexity through modular operation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention introduces intermediary substances such as organic solvents (ethyl acetate, butyl acetate, hexane) or adsorbent materials (resins, activated carbon) that facilitate the separation of malonate from fermentation broth. These intermediaries enable efficient purification by selectively binding or extracting malonate, then being removed or regenerated in subsequent steps

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If hazardous materials are used in petroleum-derived malonic acid production, then production cost is reduced, but product safety and environmental impact worsen

Engineering Contradiction:

Improveproduction costVSAvoidhazardous materials

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The invention converts potentially harmful fermentation byproducts and complex broth components into benefits through careful process design. The fermentation broth, which could be a waste stream, becomes the source of malonic acid. Hazardous petroleum-derived chemicals are replaced with benign biological systems and environmentally friendly solvents, eliminating toxic emissions while maintaining production efficiency

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 high-yield, high-purity production of bio-based malonic acid, eliminating hazardous materials and contaminants present in petroleum-derived malonic acid, and reducing environmental impact by using renewable feedstocks.

Implementation Method 1

fermenting a microorganism capable of producing malonic acid in the presence of a fermentable carbon source

Methodology Applied

Scientific EffectFermentation: Fermentation

Implementation Method 2

obtain a fermentation broth that includes an insoluble alkaline earth metal malonate salt

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Implementation Method 3

extracting the resulting insoluble alkaline earth metal malonate salt from the fermentation broth

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 4

converting the isolated alkaline earth metal malonate salt to soluble malonic acid

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 5

crystallizing the resulting soluble malonic acid

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Data Source

PatentUS11326191B2Process for purification of malonic acid from fermentation broth

Publication Date: 2022.05.10 LYGOS INC

AI summary

A process for the preparation of bio-based malonic acid and crystalline calcium malonate is provided. The calcium malonate is highly pure and provides a source of malonic acid made from a renewable carbon source rather than existing processes which rely on the use of petroleum-based products. The calcium malonate provides an improved source of malonic acid, which is important to many industrial processes.