Stacked Membrane Bioreactor for Safe H2/O2 Conversion
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Solution Overview
Problem
Current bioreactors face challenges in safely and efficiently converting CO2, H2, and O2 into useful products due to biological and design issues, including the selection of biomaterials and the safe supply of explosive gas mixtures.
Innovation Solution
A scalable bioreactor design featuring stacked perforated plates with manifolds and chambers for gas and liquid transport, incorporating biomaterials like Ralstonia eutropha and Cupriavidus, and utilizing hydrophilic and hydrophobic membranes to manage reactant concentrations and prevent explosions, with optional flame arrestors for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If H2 and O2 are supplied to the biomaterial for product conversion, then the bio-based product production efficiency is improved, but the explosion risk increases due to the potentially explosive nature of the gas mixture
Solution Approach 1:
The bioreactor is divided into multiple stacked chambers separated by membranes, with gas chambers containing H2/O2 mixtures and liquid chambers containing biomaterials. The membranes physically segment the explosive gas phases from the liquid phases, allowing efficient gas supply to biomaterials while preventing direct contact between H2 and O2 that would create explosion hazards.
Solution Approach 2:
Hydrophilic and hydrophobic membranes serve as intermediary barriers between the H2/O2 gas mixture and the biomaterial-containing liquid phase. These membranes selectively transport gases to the biomaterial surface while maintaining physical separation, enabling productive gas supply without creating explosive conditions in the liquid chamber.
2Device complexity
If phototrophic bacteria or algae are used to convert CO2 with sunlight, then the conversion process is simplified, but the requirement for large surface area and sunlight exposure reduces system scalability and efficiency in indoor settings
Solution Approach 1:
The patent replaces phototrophic conversion (relying on sunlight and large surface areas) with a chemically-driven system using H2-supplied bacteria. This substitution eliminates the need for sunlight exposure and large surface areas, enabling high-efficiency CO2 conversion in compact indoor bioreactor configurations while maintaining process simplicity.
3Device complexity
If a single-chamber bioreactor design is used, then the device structure is simplified, but the safe management of gas and liquid phases and prevention of explosive mixtures becomes difficult
Solution Approach 1:
The bioreactor employs a segmented multi-chamber structure where gas chambers and liquid chambers are separated by selective membranes. This segmentation allows independent management of H2/O2 gas phases and biomaterial-containing liquid phases, preventing explosive mixture formation while maintaining a relatively simple stacked plate construction that is easy to assemble and scale.
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 bioreactor provides a safe and efficient method for producing bio-based products, such as fuels and chemicals, by effectively converting CO2, H2, and O2, while minimizing costs and scalability limitations, and allowing for complex bioconversions and product chain configurations.
Implementation Method 1
incorporating biomaterials like Ralstonia eutropha and Cupriavidus, and utilizing hydrophilic and hydrophobic membranes to manage reactant concentrations
Implementation Method 2
utilizing hydrophilic and hydrophobic membranes to manage reactant concentrations and prevent explosions
Implementation Method 3
the biomaterial produces the bio-based product from the H2, the CO2, and the O2
Data Source
AI summary
Scalable biomaterial-based bioreactors are described. In one embodiment, the bioreactor may comprise perforated plates stacked such that the assembled bioreactor has the necessary manifolds and chambers to transport gas and liquids to a biomaterial contained within the bioreactor, and to remove the reaction products. In another embodiment, single use bioreactors are described. Methods of operating the bioreactors are also described.