Semi-Continuous Fermentation for Biomass and Oil Productivity
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Solution Overview
Problem
Existing microorganism fermentation processes, such as batch and continuous methods, face inefficiencies in maintaining high biomass and oil productivity due to time-consuming vessel turnaround procedures and difficulty in maintaining steady-state conditions, limiting overall productivity and increasing operational costs.
Innovation Solution
A semi-continuous fermentation process is employed, where a portion of the culture is harvested and fresh medium with a specific carbon-to-nitrogen ratio is added to maintain high biomass and oil productivity, allowing the culture to be sustained for an extended period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch or fed-batch fermentation processes are used, then high oil yield and ease of operation are achieved, but vessel turnaround time is long and productivity is limited
Solution Approach 1:
The patent implements a semi-continuous fermentation process where fresh medium is continuously or periodically added and culture broth is continuously or periodically removed, eliminating the idle turnaround time between batch cycles. This allows the fermentation process to operate continuously at high productivity levels while maintaining the operational simplicity of batch processes, thereby resolving the contradiction between ease of operation and productivity.
2Productivity
If continuous culture methods are used, then productivity is improved and turnaround time is reduced, but maintaining steady-state conditions is difficult and operational complexity increases
Solution Approach 1:
The patent employs a semi-continuous process that applies continuous action partially rather than fully. Instead of complete continuous operation which requires strict steady-state maintenance, the process uses periodic addition of fresh medium and periodic removal of broth, achieving high productivity while allowing operational flexibility and reducing the difficulty of maintaining optimal conditions.
3Reliability
If vessel turnaround procedures are performed between batch fermentations, then complete harvesting and processing is achieved, but time and energy are consumed
Solution Approach 1:
The semi-continuous fermentation process eliminates the complete vessel turnaround procedures between batches by maintaining continuous operation. Fresh medium is continuously or periodically added and broth is continuously or periodically removed, allowing the system to operate without idle turnaround time while still achieving complete harvesting and processing of the culture, thereby resolving the contradiction between reliability and time loss.
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 semi-continuous process achieves significantly higher volumetric biomass and oil productivity compared to traditional methods, reducing turnaround times and operational costs while maintaining high productivity levels for an extended duration.
Implementation Method 1
Heterotrophic fermentations of microorganisms including Thraustochytrid species are efficient ways of generating high value oil and biomass products
Data Source
AI summary
Provided herein are methods of culturing a microorganism. The methods include providing a container comprising one or more microorganisms in a medium, which has a first carbon to nitrogen ratio; culturing the microorganisms until the culture reaches a threshold indicator; harvesting a portion of the culture while maintaining the majority of the culture in the container; and adding fresh medium comprising a second carbon to nitrogen ratio to the container with the majority of the culture comprising the microorganisms.