Microbial Fermentation of Industrial CO for Ethanol Production
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Solution Overview
Problem
Current methods for producing ethanol and other hydrocarbon products from industrial gases, such as those produced in steam reforming processes, face challenges in scalability and integration into industrial contexts, with potential for improving hydrogen recovery and reducing greenhouse gas emissions.
Innovation Solution
A method involving the production of a gaseous substrate comprising CO through steam reforming, followed by fermentation using microorganisms in a bioreactor to produce hydrocarbon products like ethanol or 2,3-butanediol, with subsequent hydrogen recovery and recycling, and integration with steam reforming and water-gas shift processes to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional yeast-based fermentation processes using crop derived carbohydrates are used to produce ethanol, then high ethanol yield is achieved, but the cost is influenced by the value as human food or animal feed and cultivation is not economically sustainable in all geographies
Solution Approach 1:
The patent converts waste industrial gases (CO, CO2, H2) that would otherwise be harmful emissions into valuable ethanol fuel through microbial fermentation. This transforms an environmental problem into an economic opportunity, producing fuel without competing with food crops while eliminating greenhouse gas emissions.
Solution Approach 2:
The process utilizes waste gases already present in industrial settings as feedstock for ethanol production. The system essentially serves itself by using its own waste products (flared or vented gases) as inputs, eliminating the need for external carbohydrate feedstocks and their associated costs.
2Speed
If catalytic processes are used to convert gases consisting primarily of CO and/or CO and hydrogen into fuels and chemicals, then conversion speed is high, but energy costs are higher and resistance to poisoning is lower compared to biological processes
Solution Approach 1:
The patent replaces high-temperature catalytic conversion processes with mild biological fermentation processes. Instead of using energy-intensive catalytic reactors requiring high temperatures and pressures, the system uses microorganisms that operate under ambient conditions, dramatically reducing energy costs while maintaining effective conversion rates.
3Use of energy by moving object
If waste gases from steam reforming are flared or used as fuel, then energy recovery is achieved, but greenhouse gas CO2 emissions are produced
Solution Approach 1:
The patent transforms the harmful CO2 emissions from flaring waste gases into valuable ethanol fuel through microbial fermentation. Instead of burning CO-containing gases and releasing CO2, the system ferments these gases into liquid fuel that can be used as a transportation fuel, effectively converting a greenhouse gas problem into a renewable fuel solution.
Solution Approach 2:
The process changes the chemical parameters of waste gases by converting CO and CO2 into ethanol through biological fermentation. This parameter transformation converts gaseous emissions into liquid fuel products, fundamentally altering the state and utility of the waste materials while eliminating direct emissions.
4Quantity of substance
If hydrogen is recovered from steam reforming processes, then hydrogen availability is improved, but process complexity increases
Solution Approach 1:
The patent creates a multi-functional system where the fermentation process simultaneously consumes CO and CO2 from waste gases while producing ethanol and regenerating hydrogen. This hydrogen regeneration eliminates the need for separate hydrogen recovery and purification systems, reducing overall process complexity while maintaining high hydrogen availability.
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 the efficient conversion of industrial gases into valuable hydrocarbon products while reducing carbon emissions, improving hydrogen recovery, and optimizing energy use within industrial processes.
Implementation Method 1
fermenting the culture in the bioreactor to produce one or more hydrocarbon products
Implementation Method 2
organisms that use the acetyl coenzyme A (acetyl CoA) biochemical pathway of autotrophic growth (also known as the Woods-Ljungdahl pathway and the carbon monoxide dehydrogenase / acetyl CoA synthase (CODH/ACS) pathway)
Implementation Method 3
passing at least a portion of a gas stream exiting the bioreactor to: i. a pressure swing adsorption (PSA) module and recovering hydrogen from the exit gas stream
Implementation Method 4
producing a gaseous substrate comprising CO in a steam reforming process, wherein the steam reforming process comprises a steam reforming step
Implementation Method 5
a water gas shift step
Data Source
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AI summary
Methods and systems for the production of hydrocarbon products, including providing a substrate comprising CO to a bioreactor containing a culture of one or more micro-organisms; and fermenting the culture in the bioreactor to produce one or more hydrocarbon products. The substrate comprising CO is derived from an industrial process selected from the group comprising steam reforming processes, refinery processes, steam cracking processes, and reverse water gas shift processes.