Polyhydroxyalkanoate Cake Production Without Heated Drying
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Solution Overview
Problem
The existing methods for producing polyhydroxyalkanoate (PHA) powder require energy-intensive drying processes, re-wetting procedures that consume additional water and energy, and result in larger particle sizes, foaming, and increased use of surfactants, which diminish sustainability and regulatory acceptance.
Innovation Solution
A method to produce PHA cake by eliminating heated drying and re-wetting processes, using alternating solvent washes and filtration to maintain a wetted state, resulting in smaller particle sizes and reduced additive requirements, suitable for formulations like coatings and paper products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If PHA is dried in an oven to produce dry powder, then the PHA can be stored and shipped, but energy consumption increases and particle size increases requiring re-wetting processes
Solution Approach 1:
The patent changes the physical state parameter of PHA from completely dried powder to a wet cake form containing 10-50% water. This parameter change eliminates the need for high-temperature oven drying, significantly reducing energy consumption while maintaining the PHA in a stable, transportable semi-solid form that can be directly processed without re-wetting
2Ease of operation
If dried PHA powder is re-wetted for use, then dispersion is achieved, but additional water and energy are consumed
Solution Approach 1:
The patent performs preliminary wetting during the extraction process itself, producing PHA cake that already contains 10-50% water. This preliminary action eliminates the need for subsequent re-wetting operations, saving both time and additional water while maintaining good dispersion properties through the retained moisture
3Ease of manufacture
If dried PHA powder is processed, then it can be formulated, but surfactant levels must be increased to wet-out particles
Solution Approach 1:
The patent changes the moisture content parameter from near-zero in dried powder to 10-50% in the cake form. This parameter change provides inherent wetting capability that eliminates or reduces the need for surfactants during formulation, allowing direct processing with minimal or no additional chemical additives
4Weight of stationary object
If heated drying is applied to PHA, then powder is produced, but particle size increases reducing film formation
Solution Approach 1:
The patent changes the thermal processing parameter by eliminating high-temperature drying entirely. The PHA is processed and recovered in a wet state at lower temperatures, preserving smaller particle sizes that are critical for good film formation properties, while still achieving a stable semi-solid cake form for handling
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 PHA cake process reduces energy consumption, minimizes surfactant use, and enhances processability, sustainability, and film formation propensity, while maintaining regulatory biodegradability and compostability.
Implementation Method 1
the PHA is washed back and forth in an alternating manner with organic and inorganic solvents, such as an alcohol and water
Implementation Method 2
cross flow filtration
Data Source
AI summary
A cake material is disclosed, made up of polyhydroxyalkanoate (PHA) cake that is formed directly from biomass and subsequent purification processes absent any heated drying step, with a moisture content of no less than about 5% by weight, and a Dv (90) particle size of no more than about 8 microns.