Carboxylic acid production method
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Solution Overview
Problem
Existing methods fail to adequately enhance phase separation between the aqueous and organic phases during the extraction of carboxylic acids from fermentation broths, even when using microfiltration and ultrafiltration membranes.
Innovation Solution
Passing a carboxylic acid-containing fermentation broth through a nanofiltration membrane before extraction, adjusting the pH to 4.5 or less, and optionally removing insoluble substances with microfiltration, to accelerate phase separation and increase purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microfiltration and ultrafiltration membranes are used for filtering fermentation broth, then some solids are removed, but phase separation between aqueous and organic phases is still insufficient
Solution Approach 1:
The patent changes the key parameter of membrane pore size from micrometer-scale (microfiltration) and nanometer-scale (ultrafiltration) to sub-nanometer scale (nanofiltration). This parameter change enables the membrane to effectively remove intermediate-phase-forming substances that pass through larger pores, thereby achieving complete phase separation without increasing process complexity
Solution Approach 2:
The nanofiltration membrane acts as an intermediary between the fermentation broth and the extraction process. It selectively removes substances that would otherwise form intermediate phases during extraction, enabling smooth phase separation between aqueous and organic phases without requiring additional complex treatment steps
2Productivity
If nanofiltration membrane is used for filtering fermentation broth, then phase separation is accelerated and purity is increased, but filtration pressure and energy consumption increase
Solution Approach 1:
The nanofiltration is performed as a preliminary step before extraction to remove substances that would form intermediate phases. By conducting this high-energy filtration upfront, the subsequent extraction process benefits from improved phase separation without requiring additional energy input, as the problematic substances have already been removed
Solution Approach 2:
The patent utilizes the phase transition properties of different substances during nanofiltration. The membrane selectively allows certain molecules to pass while retaining others based on their size and properties, enabling efficient separation. This selective phase transition behavior achieves fast phase separation during extraction without requiring sustained high energy input throughout the entire process
3Ease of manufacture
If fermentation broth is directly extracted without nanofiltration, then process is simpler, but intermediate phases form and interfere with separation
Solution Approach 1:
The patent extracts and removes the harmful substances that cause intermediate phase formation through nanofiltration before the main extraction process. By taking out these problematic components selectively, the subsequent extraction proceeds without intermediate phase interference, maintaining process simplicity while eliminating the harmful effect
Solution Approach 2:
The nanofiltration step performs a preliminary anti-action by removing substances that would otherwise create intermediate phases during extraction. This preventive measure eliminates the harmful effect before it can manifest, allowing the extraction process to proceed smoothly without interference while maintaining relative process simplicity
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 method efficiently accelerates phase separation and enhances the recovery of carboxylic acids by inhibiting the formation of intermediate phases, improving the purity and recovery rate.
Implementation Method 1
filtering a carboxylic acid-containing fermentation broth by passing the fermentation broth through a nanofiltration membrane
Implementation Method 2
passing the fermentation broth through a nanofiltration membrane, to obtain a carboxylic acid-containing filtrate
Implementation Method 3
extracting the carboxylic acid from the carboxylic acid-containing filtrate obtained in the step (A) using an extraction solvent which undergoes phase separation with the filtrate
Implementation Method 4
collecting a carboxylic acid extract phase-separated from the aqueous phase
Implementation Method 5
the step of removing the insoluble substances is the step of passing the carboxylic acid-containing fermentation broth through a microfiltration membrane
Data Source
Figure 1
Figure 2(a)~2(b)
AI summary
The present invention allows for an efficient production of a carboxylic acid, by providing a method of producing a carboxylic acid, which includes the following steps (A) and (B): (A) filtering a carboxylic acid-containing fermentation broth by passing said fermentation broth through a nanofiltration membrane, to obtain a carboxylic acid-containing filtrate from the permeate side of the membrane; and (B) extracting the carboxylic acid from the carboxylic acid-containing filtrate obtained in the step (A) using an extraction solvent which undergoes phase separation with the filtrate, and collecting a carboxylic acid extract phase-separated from the aqueous phase.