Simulated Moving Bed Separators for High Purity Fructose
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Solution Overview
Problem
Conventional methods for producing high-purity fructose face challenges such as energy-intensive concentration processes, oligosaccharide accumulation, and reduced throughput due to incomplete isomerization and recycling of glucose-rich raffinate, leading to decreased fructose productivity and increased energy costs in the corn sweetener industry.
Innovation Solution
A method involving a series of simulated moving bed (SMB) chromatographic separators is used to process a feedstock containing glucose, fructose, and inert components, where the glucose-rich raffinate is recycled for additional isomerization and the fructose extract is further purified in a second SMB separator to achieve a high-purity fructose product exceeding 95% purity, while minimizing oligosaccharide content and water usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional SMB chromatography is used to produce fructose-rich extract, then fructose purity of 80-90% is achieved, but energy consumption increases due to concentration requirements
Solution Approach 1:
The patent divides the SMB system into multiple separators (first SMB separator and second SMB separator) operating in series. The first separator produces an intermediate fructose-rich extract (80-90% purity), which is then further purified by the second separator to achieve high purity (>95%) without requiring energy-intensive concentration steps. This segmentation allows progressive purification at lower energy costs.
Solution Approach 2:
The patent implements preliminary isomerization of glucose to fructose before the separation process, and preliminary concentration of the feedstock to optimize the input composition. This preliminary preparation reduces the energy burden on subsequent purification stages by optimizing the feed composition for the SMB separators.
2Productivity
If glucose-rich raffinate is recycled to isomerization columns to increase conversion, then fructose production increases, but throughput decreases due to reaction time requirements
Solution Approach 1:
The patent implements a continuous recycling loop where glucose-rich raffinate from the first SMB separator is continuously fed back to the isomerization column. This continuous operation maintains steady-state conversion without interruption, maximizing fructose production while minimizing idle time. The system operates continuously rather than in batches, ensuring constant useful action.
Solution Approach 2:
The patent uses feedback control where the composition of the raffinate stream is monitored and the recycling rate is adjusted accordingly. This feedback mechanism optimizes the balance between conversion efficiency and throughput by dynamically adjusting how much raffinate is recycled versus purged, preventing oligosaccharide accumulation while maximizing fructose production.
3Productivity
If raffinate is recycled to isomerization chamber, then glucose conversion to fructose increases, but oligosaccharide content accumulates
Solution Approach 1:
The patent extracts and removes oligosaccharides from the recycling loop by using the SMB separators to separate them from the glucose-fructose mixture. The oligosaccharides are directed to waste streams rather than being recycled, preventing their accumulation in the isomerization chamber while maintaining high glucose conversion efficiency.
Solution Approach 2:
The patent changes the separation parameters of the SMB system to optimize oligosaccharide removal. By adjusting flow rates, residence times, and separator configurations, the system achieves selective separation of oligosaccharides from the recyclable glucose-fructose stream, maintaining purity while enabling continuous recycling.
4Manufacturing precision
If fructose syrup is concentrated to 90-95% DS for crystallization, then high purity fructose crystals are produced, but energy input increases significantly
Solution Approach 1:
The patent replaces the mechanical/thermal concentration process (evaporation to 90-95% DS) with a chromatographic separation system (SMB separators). The SMB system achieves high purity fructose extraction through adsorption and desorption mechanisms rather than thermal evaporation, dramatically reducing energy input while maintaining or improving purity levels.
Solution Approach 2:
The patent changes the fundamental separation parameter from thermal concentration to chromatographic partitioning. Instead of using temperature and evaporation rate as control parameters, the system uses mobile phase composition, flow rate, and resin selectivity to achieve separation, operating in a low-energy parameter space.
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 approach enhances fructose productivity, reduces energy costs by minimizing water usage, and allows for flexibility in responding to market demands by producing high-purity fructose with reduced oligosaccharide content, thereby improving the economic viability of fructose production.
Implementation Method 1
Simulated moving bed (SMB) chromatographic separators for purification of a feedstock
Implementation Method 2
These columns contain the immobilized enzyme xylose isomerase (colloquially known as glucose isomerase), which is able to convert approximately 50% of the glucose to fructose at equilibrium
Data Source
AI summary
A method of enriching a material comprising glucose, fructose, and one or more components inert to isomerization using chromatography to produce a high purity fructose product. An embodiment of the method purifies high fructose corn syrup from a feedstock into three product streams: a first fraction rich in glucose, a second fructose product comprising an extract of fructose purity exceeding about 95%, and a third less pure fructose fraction comprising fructose ranging from about 55% to about 90% fructose purity. The third less pure fructose fraction may be combined with 42% fructose syrup to produce saleable mid-purity fructose product, such as having 55% fructose purity. An SMB system is also disclosed and comprises a first SMB separator, a second SMB separator, and an isomerization chamber.