Integrated Methanol Synthesis Fermentation System
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Solution Overview
Problem
Current biomolecule production via fermentation is cost-intensive due to the need for energy-consuming and costly methanol distillation columns, which limits the scalability and sustainability of processes like methylotroph fermentation for producing recombinant proteins and single cell protein.
Innovation Solution
Integrating upstream methanol synthesis with downstream methylotroph fermentation and separation processes, eliminating the need for methanol distillation by using unrefined methanol and waste steam for energy and temperature control, while recycling carbon dioxide to enhance methanol production and oxygenation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If methanol distillation columns are used to purify methanol before fermentation, then the purity of methanol is improved, but the energy consumption and production cost increase significantly
Solution Approach 1:
The patent extracts and removes the distillation step from the traditional fermentation process. By using unrefined methanol directly from synthesis without subjecting it to distillation, the system eliminates the energy-intensive purification step while maintaining fermentation effectiveness through the use of robust methylotrophic organisms that can tolerate impurities.
Solution Approach 2:
The patent changes the purity parameter requirement for methanol input. Instead of requiring high-purity distilled methanol, the system accepts unrefined methanol with lower purity (containing water and other impurities), thereby eliminating the need for distillation columns and reducing energy consumption while maintaining productive fermentation.
2Manufacturing precision
If distillation columns are installed for methanol purification, then the quality of fermentation substrate is improved, but the device complexity and capital cost increase
Solution Approach 1:
The patent removes the distillation column equipment from the process flow. By directly using unrefined methanol from the synthesis unit, the system eliminates complex purification equipment while maintaining effective fermentation through the selection of tolerant methylotrophic organisms.
3Use of energy by moving object
If unrefined methanol is used directly without distillation, then the energy consumption and cost are reduced, but the purity of fermentation substrate decreases
Solution Approach 1:
The patent converts the previously harmful impurities in unrefined methanol into a beneficial feature. By selecting methylotrophic organisms that are tolerant of or even thrive on unrefined methanol containing water and other impurities, the system eliminates the need for costly distillation while maintaining or improving process efficiency. The impurities that were once problematic become acceptable or even advantageous.
4Productivity
If traditional fermentation processes are used with refined methanol, then the biomolecule production efficiency is maintained, but the overall process sustainability and scalability are limited due to high costs
Solution Approach 1:
The patent merges the methanol synthesis unit with the fermentation unit into an integrated system. By directly connecting unrefined methanol output from synthesis to the fermentation process, the system eliminates intermediate purification steps, reduces overall process cost, and improves sustainability while maintaining production efficiency through the use of robust methylotrophic organisms.
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 integration significantly reduces the overall cost of biomolecule production, enhances process efficiency, and increases sustainability by eliminating the need for costly distillation columns and energy-intensive steps, making large-scale biomolecule production more viable.
Implementation Method 1
introducing an oxygen-containing gas into the aqueous fermentation medium within the fermentation vessel for a duration sufficient to expand a population of methylotrophic organisms
Implementation Method 2
introducing an oxygen-containing gas into the aqueous fermentation medium via jet aeration, surface aeration, or fine bubble diffusers
Implementation Method 3
expand a population of methylotrophic organisms within the aqueous fermentation medium
Data Source
AI summary
The present disclosure relates to an integrated methanol synthesis and fermentation system for the production of whole cells and biomolecules, and methods of using the same. In one embodiment, a system comprises a methanol synthesis apparatus adapted to produce unrefined methanol; a mixing apparatus adapted to receive unrefined methanol from the methanol synthesis apparatus; and a metering apparatus having at least one first input port in communication with mixing apparatus and at least one second output port in communication with a fermentation vessel.