Polyalkylene Glycol Foam Control in Fermentation

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Solution Overview

Problem

Current antifoam agents used in alcohol-based fuel production through fermentation, such as propylene oxide (PO)/ethylene oxide (EO) diols, exhibit low persistency, requiring frequent additions to control foaming in the fermentation broth, which complicates the process and increases costs.

Innovation Solution

The use of polyalkylene glycols with a functionality greater than 2, preferably 3, 4, 5, or 6, is introduced as a foam control agent in the fermentation process, which can be added continuously or intermittently to the broth in amounts sufficient to maintain foam levels below desired limits, potentially reducing the frequency of additions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If propylene oxide/ethylene oxide diols are used as foam control agents, then foam control is achieved, but persistency is low requiring frequent additions

Engineering Contradiction:

Improvefoam control effectivenessVSAvoidpersistency of foam control

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent changes the chemical parameter of the foam control agent by using polyalkylene glycols with functionality greater than 2 (triols, tetrols, etc.) instead of conventional diols. This parameter change increases the molecular complexity and interaction capability with foam structures, resulting in improved persistency and reduced frequency of additions while maintaining effective foam control throughout the fermentation process

Inventive Principle:

Principle #35Parameter changes

2Reliability

If frequent additions of foam control agents are made, then foam control is maintained, but process complexity increases

Engineering Contradiction:

Improvefoam control maintenanceVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements continuous or intermittent addition of polyalkylene glycol foam control agents that provide sustained foam control action. The higher functionality polyalkylene glycols maintain effective foam suppression over extended periods, enabling a more continuous and streamlined process rather than repeated discrete additions, thereby reducing operational complexity while ensuring reliable foam control

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If frequent additions of defoamers are required, then foam control is achieved, but costs increase

Engineering Contradiction:

Improvefoam control effectivenessVSAvoidamount of defoamer required

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent employs polyalkylene glycols with functionality greater than 2 that provide self-sustaining foam control through their molecular structure. The higher functionality creates multiple interaction sites that continuously suppress foam formation without requiring external defoamer additions, allowing the system to self-regulate foam levels throughout the fermentation process, thereby reducing defoamer consumption and associated costs

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9150886B2Foam control of alcoholic fermentation processes

Publication Date: 2015.10.06 DOW BRASIL SUDESTE IND

AI summary

The method of producing bioethanol by sugarcane fermentation is improved by using a polyalkylene glycol with a hydroxyl functionality of greater than 2 as a foam controlling agent.