Malonic Acid Diester Preparation Through Fermentation Broth Purification

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Solution Overview

Problem

Existing methods for extracting and purifying bio-based malonate and its diester derivatives face challenges in integrating efficient extraction and purification processes into the overall production flow, particularly from fermentation broths.

Innovation Solution

The methods involve ultrafiltration, nanofiltration, reactive extraction, and thermal decomposition to isolate and purify diesters of malonic acid, utilizing organic solvents and acidic catalysts to selectively convert malonic acid salts into diesters, and include steps like centrifugation, evaporation, and distillation to achieve high purity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional extraction and purification methods are used for bio-based malonate, then the process can be integrated into production flow, but the efficiency and purity of diester derivatives are insufficient

Engineering Contradiction:

Improveprocess efficiencyVSAvoidpurity of diester derivatives

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The purification process is divided into multiple sequential stages: fermentation broth filtration to remove biomass, concentration of malonate from filtrate, esterification to convert malonate to diester, and final purification. Each stage targets specific impurities or transformations, enabling both high efficiency and high purity through systematic breakdown of the overall process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Organic solvents serve as intermediaries in the esterification process, facilitating the conversion of malonate to diester derivatives. The solvents enable selective extraction and reaction while maintaining process efficiency, acting as mediators between the aqueous fermentation broth and the final organic diester product

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If multiple purification steps are implemented to achieve high purity diesters, then manufacturing precision improves, but device complexity and operating costs increase

Engineering Contradiction:

Improvepurity of diester derivativesVSAvoidcomplexity of purification process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple functions are merged into integrated process units: filtration and concentration are combined in membrane separation systems, esterification and purification are integrated in reactive extraction columns. This merging reduces the number of separate devices and operations while maintaining high purity outcomes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The purification system employs multi-functional components that can handle multiple tasks: organic solvents serve as reaction media, extraction agents, and purification media simultaneously; membrane filters perform both concentration and purification functions. This multi-functionality reduces overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If conventional purification methods are used, then device complexity is reduced, but hazardous contaminants remain in the final product

Engineering Contradiction:

Improvesimplicity of purification processVSAvoidhazardous contaminants

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The process converts potentially harmful intermediate compounds into beneficial final products through controlled esterification. Impurities and byproducts that would normally require complex removal are transformed into the desired diester derivatives or converted into removable forms, eliminating hazardous contaminants while simplifying the overall process

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

These methods enhance process efficiency, yield high-purity diesters of malonic acid, reduce capital and operating costs, and eliminate hazardous contaminants, while producing valuable byproducts like ammonium sulfate.

Implementation Method 1

filtering the fermentation medium via ultrafiltration or nanofiltration

Methodology Applied

Scientific EffectUltrafiltration:

Implementation Method 2

filtering the fermentation medium via ultrafiltration or nanofiltration

Methodology Applied

Scientific EffectNanofiltration:

Implementation Method 3

extracting the diester into an organic solvent, preferentially over the monoester, if present

Methodology Applied

Scientific EffectReactive extraction: Liquid-Liquid Extraction

Implementation Method 4

contacting an aqueous solution or aqueous mixture of a malonic acid salt with a lower alkanol and an acid under conditions suitable to provide a diester of malonic acid and the lower alkanol

Methodology Applied

Scientific EffectEsterification: Catalysis

Implementation Method 5

separating the fermentation medium from the biomass by centrifugation

Methodology Applied

Scientific EffectCentrifugation: Centrifugal Separation

Implementation Method 6

concentrating the filtered fermentation medium

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 7

distilling the resulting organic phase to separate alcohol, solvent, and impurities from the diester of malonic acid

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS20250320532A1Preparing diesters of malonic acid

Publication Date: 2025.10.16 LYGOS INC

AI summary

Methods for the preparation and isolation of malonic acid, a salt or a diesters thereof, preferably bio-based versions of the foregoing are provided.