Renewable Diacid Production via Metathesis and Microbial Oxidation
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Solution Overview
Problem
Current methods for producing long-chain diacids are inefficient, requiring extensive purification and often rely on non-renewable sources, with a need for improved selectivity and waste minimization, as well as the ability to produce diacids of varying chain lengths and characteristics.
Innovation Solution
A process combining metathesis and microbial oxidation using a C6-C22 fatty acid ester feedstock, where metathesis reaction conditions with C2-C4 alkenes produce renewable alkenes and fatty acid esters, followed by microbial oxidation to yield diacids, allowing for efficient recovery and production of high-purity renewable diacids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microbial oxidation is conducted first followed by metathesis, then diacids can be produced from renewable feedstock, but extensive purification is required to remove impurities that poison metathesis catalysts
Solution Approach 1:
The patent applies preliminary action by performing metathesis reaction before microbial oxidation. The metathesis step converts fatty acid esters to metathesis products (alkenes and saturated fatty acid esters) that are then subjected to microbial oxidation. This sequence reversal ensures that the metathesis catalyst is not exposed to poisoning impurities generated during fermentation, thereby maintaining catalyst activity without requiring extensive purification steps.
2Quantity of substance
If traditional chemical methods are used for diacid production, then long-chain diacids can be prepared, but the processes rely on non-renewable feedstocks and require multiple reaction steps
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional chemical feedstocks (benzene, 1,3-butadiene) to renewable fatty acid esters. The process modifies the chemical parameters of the feedstock while maintaining the ability to produce long-chain diacids. The metathesis reaction specifically targets the carbon chain length control, enabling production of diacids with C10-C22 chains from renewable sources, thus achieving both quantity and sustainability goals.
3Reliability
If fermentation is used to produce long-chain diacids, then renewable diacids can be obtained, but selectivity towards desired chain lengths is limited and waste fractions are not utilized
Solution Approach 1:
The patent applies preliminary action by performing metathesis reaction before microbial oxidation to pre-sort the carbon chains. The metathesis reaction with C2-C4 alkenes produces metathesis products with specific chain lengths that are then selectively oxidized by microorganisms. This preliminary structural modification enables the fermentation step to produce diacids with improved chain length selectivity, addressing the productivity issue while maintaining product purity.
4Manufacturing precision
If extensive purification steps are applied to fermentation broth, then high-purity diacids can be obtained, but the process becomes incompatible with industrial scale
Solution Approach 1:
The patent applies preliminary action by performing metathesis reaction before microbial oxidation to pre-purify the substrate. The metathesis products obtained are inherently cleaner and more suitable for fermentation, reducing the burden on post-fermentation purification steps. This approach maintains high diacid purity while simplifying the overall manufacturing process for industrial scalability.
5Reliability
If metathesis catalysts are exposed to fermentation broth impurities, then catalyst activity is reduced, but the process complexity increases to prevent this
Solution Approach 1:
The patent applies inversion by reversing the conventional sequence of operations. Instead of performing microbial oxidation first and then metathesis (which would expose the catalyst to poisoning impurities), the process performs metathesis first followed by microbial oxidation. This inverted sequence protects the metathesis catalyst from impurities while maintaining process efficiency and avoiding additional complexity.
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 process enables the production of renewable diacids with improved selectivity and flexibility, utilizing renewable raw materials, reducing chemical and solvent use, and generating valuable by-products, while minimizing waste and enabling the production of diacids not feasible with prior art methods.
Implementation Method 1
subjecting the feedstock to metathesis reaction conditions in the presence of an alkene selected from C2, C3, C4 alkenes and a metathesis catalyst
Implementation Method 2
subjecting a part of the metathesis products after optional pretreatment(s), to microbial oxidation to yield diacids in a fermentation broth
Data Source
AI summary
A process for combined renewable 1-decene and renewable carboxylic diacid production from a fatty acid ester containing feedstock, wherein the feedstock is first subjected to metathesis reaction conditions, recovery of 1-decene and then to microbial oxidation to yield diacids in a fermentation broth. Diacids of unusual carbon chains lengths are thereby obtainable.