Microjet Reactor Cell Lysis for Scalable Biomass Extraction

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Solution Overview

Problem

Existing methods for microbial cell lysis, such as ultrasonic sonication, bead milling, French press, and high-pressure homogenization, face challenges including poor scalability, high equipment wear, and high operational costs, making them unsuitable for large-scale biomass processing.

Innovation Solution

A microjet reactor is used for cell lysis by colliding liquid jets with nozzle diameters between 50 μm-2000 μm and hydraulic pressures of 5-1000 bar, achieving cell destruction through kinetic energy conversion into mechanical forces, enabling simultaneous extraction of cellular constituents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ultrasonic sonotrode immersion process is used for cell lysis, then cell lysis effectiveness is improved, but equipment wear increases and scalability deteriorates

Engineering Contradiction:

Improvecell lysis effectivenessVSAvoidscalability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical ultrasonic sonotrode system with a high-pressure homogenization system using a valve and pump. This substitution eliminates the wear-prone ultrasonic horn while achieving effective cell lysis through high-pressure forcing of cell suspension through a narrow valve opening, thereby improving scalability without sacrificing lysis effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention employs hydraulic principles by using a pump to generate high pressure (up to 2000 bar) to force the cell suspension through a valve. This hydraulic approach enables scalable cell lysis processing by replacing the contact-intensive ultrasonic method with a pressure-driven flow system that can handle larger volumes efficiently.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If high-pressure homogenization is used for cell lysis, then scalability is improved, but equipment wear and operational costs increase

Engineering Contradiction:

ImprovescalabilityVSAvoidequipment wear

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent employs a disposable valve design that can be easily replaced or cleaned between runs. This approach addresses the wear issue by using inexpensive, replaceable components rather than expensive, wear-prone ultrasonic sonotrodes, enabling high scalability without prohibitive equipment replacement costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If French press process is used for cell lysis, then cell destruction effectiveness is improved, but scalability and availability for large volumes deteriorates

Engineering Contradiction:

Improvecell destruction effectivenessVSAvoidavailability for large volumes

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention replaces the manual French press mechanical system with an automated high-pressure pump and valve system. This substitution maintains the effective cell destruction mechanism (forcing through a narrow opening) while enabling continuous processing of large volumes, thereby improving availability and scalability without sacrificing lysis effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If bead milling is used for cell lysis, then cell lysis effectiveness is improved, but scalability deteriorates and availability for small sample volumes is limited

Engineering Contradiction:

Improvecell lysis effectivenessVSAvoidscalability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the bead milling mechanical agitation system with a high-pressure homogenization system using a valve and pump. This substitution eliminates the scalability limitations of bead milling by using a pressure-driven flow system that can easily scale from small to large volumes while maintaining effective cell lysis through the high-velocity passage through the valve opening.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 microjet reactor efficiently lyses cells on a large scale with minimal equipment wear, allowing for scalable and cost-effective extraction of valuable substances like omega-3 fatty acids from microorganisms.

Implementation Method 1

nozzle diameters of the microjet reactor are in the range 50 μm-2000 μm and the hydraulic nozzle primary pressures of the microjet reactor are in the range of 5-1000 bar

Methodology Applied

Scientific EffectHydraulic pressure to kinetic energy conversion:

Implementation Method 2

achieving cell destruction through kinetic energy conversion into mechanical forces

Methodology Applied

Scientific EffectKinetic energy conversion to mechanical forces:

Implementation Method 3

cell lysis takes place by the high shear forces that occur

Methodology Applied

Scientific EffectShear force: Shear Stress

Implementation Method 4

possible cavitation due to rapid decompression in the gap

Methodology Applied

Scientific EffectCavitation: Cavitation

Data Source

PatentUS12584092B2Use of a microjet reactor for processing biomass

Publication Date: 2026.03.24 MYBIOTECH GMBH

AI summary

The invention relates to the use of microjet reactor for processing biomass. The cell lysis of flowable biomass is thereby carried out by means of multiple high-speed liquid jets which collide with one another, wherein the liquid jets contain the cells or consist wholly of the flowable cell mass, wherein intact or wholly or partially lysed biomass is added to at least one of the colliding high-speed liquid jets, and an extraction takes place simultaneously with the collision of the liquid jets or subsequently thereto. The lysis of the cells is initiated or facilitated by the forces that occur on acceleration, introduction of the acceleration, collision of the jets and mixing of the jet constituents.