Oligosaccharide Hydrolysis Process for Monosaccharide Yield
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Solution Overview
Problem
The existing hydrolysis processes for converting oligosaccharides to monosaccharides in biofuel production are limited by high operating costs, significant by-product formation, and inefficiencies due to the formation of reversion sugars, which cap the operating concentrations and negatively impact the economics of the process.
Innovation Solution
A method involving a hydrolysis composition with at least 20 wt % sugar equivalents, where oligosaccharides are contacted with a catalyst to form monosaccharides and reversion sugars, with a further hydrolysis step to convert reversion sugars into additional monosaccharides, allowing for higher oligosaccharide concentrations and reduced by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acid-catalyzed hydrolysis is used to convert oligosaccharides to monosaccharides, then monosaccharide production is achieved, but fermentation inhibitors (HMF, organic acids) are formed as by-products
Solution Approach 1:
The hydrolysis process is divided into multiple stages with different acid concentrations. A first stage uses higher acid concentration to rapidly break down oligosaccharides, followed by a second stage with lower acid concentration to complete hydrolysis while minimizing by-product formation. This segmentation allows optimization of each stage for its specific function.
Solution Approach 2:
The process performs preliminary concentration of the oligosaccharide stream to at least 20 wt% sugar equivalents before hydrolysis. This preliminary action increases reaction efficiency and reduces the volume of material requiring subsequent processing, thereby reducing overall by-product formation while maintaining high monosaccharide yields.
2Object-generated harmful factors
If overliming is applied to reduce fermentation inhibitors, then HMF concentration is reduced, but organic acids remain and large amounts of waste gypsum are generated
Solution Approach 1:
The invention extracts and removes fermentation inhibitors through selective separation processes before the hydrolysis step. By removing inhibitors from the oligosaccharide stream prior to hydrolysis, the need for subsequent overliming is eliminated, avoiding gypsum waste generation while still protecting the monosaccharides from degradation.
Solution Approach 2:
The process performs preliminary removal of fermentation inhibitors from the oligosaccharide stream before hydrolysis. This preliminary purification action prevents inhibitor formation during hydrolysis and eliminates the need for corrective overliming operations, thereby avoiding waste generation.
3Stability of the object's composition
If reversion sugars are formed during hydrolysis, then equilibrium reactions occur, but operating concentrations are capped and process economics are adversely affected
Solution Approach 1:
The process dynamically adjusts operating conditions to favor forward hydrolysis reactions. By controlling parameters such as acid concentration, temperature, and residence time, the system maintains conditions that promote oligosaccharide breakdown while suppressing the reverse condensation reaction that forms reversion sugars, thereby enabling higher operating concentrations.
Solution Approach 2:
The invention changes key process parameters including acid concentration, temperature, and residence time to shift the equilibrium away from reversion sugar formation. By optimizing these parameters, the process achieves higher operating concentrations without significant reversion sugar accumulation, improving overall productivity and economics.
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 enhances the yield and quality of monosaccharides by reducing reversion sugars, lowering operating costs, and enabling higher oligosaccharide concentrations, thus improving the overall efficiency and economics of the hydrolysis process.
Implementation Method 1
contacting the hydrolysis composition with a catalyst in a first reactor to hydrolyze at least a portion of the first oligosaccharide to form a first product composition comprising a first monosaccharide
Data Source
AI summary
Provided is a method comprising (a) providing a hydrolysis composition of at least 20 wt % of sugar equivalents, wherein the hydrolysis composition comprises a first oligosaccharide, water, optionally a soluble aromatic compound, (b) contacting the hydrolysis composition with a catalyst in a first reactor to hydrolyze at least a portion of the first oligosaccharide to form a first product composition comprising a first monosaccharide and a second oligosaccharide, (c) separating the first monosaccharide from the first product composition to form a second product composition comprising the second oligosaccharide, wherein at least a portion of the second oligosaccharide is a reversion sugar, and (d) converting via a further hydrolysis step at least a portion of the second oligosaccharide to form a third product composition comprising a second monosaccharide.