Oxygen-Free Single-Cell Protein Processing With Density Separation

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Solution Overview

Problem

Existing methods for separating solids from liquids in process streams are inefficient, costly, require frequent maintenance, and result in high emissions and capital costs, failing to adequately integrate into production facilities and produce valuable products.

Innovation Solution

A mechanical device is used to separate suspended solids from liquids by adding non-condensable media to reduce liquid density, followed by a mechanical separation process, and further processing to produce valuable animal feed products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If gravity separation is used to separate solids from liquids, then the process is simple to operate, but the separation efficiency is low and the processing time is long

Engineering Contradiction:

Improveease of operationVSAvoidseparation efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces gravity-based mechanical separation with a biological system (microorganisms) that actively consume and transform target substances, converting a passive physical separation process into an active biological treatment process that achieves both high efficiency and operational simplicity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The microorganisms perform the separation function autonomously by metabolically consuming the target substances in the liquid phase, eliminating the need for complex external separation equipment and operators while maintaining continuous processing

Inventive Principle:

Principle #25Self-service

2Reliability

If conventional separation equipment is used, then the initial capital cost is high, but the separation performance is adequate

Engineering Contradiction:

Improveseparation performanceVSAvoidcapital cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses readily available, low-cost microorganisms that can be easily cultured and deployed, replacing expensive specialized separation equipment with inexpensive biological agents that perform the separation function through metabolic activity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the fundamental parameter of separation from physical force-based (gravity, centrifugal) to biochemical-based (metabolic consumption), enabling the use of simple bioreactors instead of complex mechanical separation systems

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional processing methods are used, then the process is well-established, but energy consumption is high and emissions are high

Engineering Contradiction:

Improveprocess stabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent introduces oxygen as a terminal electron acceptor in the microbial respiratory pathway, accelerating the degradation of organic substances and enabling complete mineralization to CO2 and H2O, which reduces energy consumption compared to thermal processing methods while maintaining process reliability

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

Solution Approach 2:

The patent creates an optimized aerobic environment for microorganism growth and activity, controlling oxygen availability to maximize metabolic efficiency and minimize energy losses, thereby reducing overall energy consumption while maintaining stable processing

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Manufacturing precision

If density reduction with non-condensable media is applied, then liquid density decreases improving separation, but the process complexity increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses microorganisms as intermediary agents that biologically mediate the separation process by consuming target substances, replacing the need for direct physical density modification methods and simplifying the overall process while maintaining high separation efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances solid-liquid separation efficiency, reduces energy and operating costs, decreases greenhouse gas emissions, and increases the value of products, aligning with regulatory standards for lower carbon intensity fuels.

Implementation Method 1

adding non-condensable media to reduce liquid density, followed by a mechanical separation process

Methodology Applied

Scientific EffectDensity difference: Density Gradient

Data Source

PatentUS20250302069A1Single cell protein process and product- oxygen free

Publication Date: 2025.10.02 ICM INC

AI summary

This disclosure describes methods to separate solids from liquids in a production facility. A process separates components in the process stream by applying non-condensable media to create density differences and then using a mechanical device to separate the solids from the liquids based on the density difference. The process produces the liquids and solids, which may be further processed to create valuable animal feed products.