Continuous Tubular Membrane Bioreactor for Cyclodextrins From Cellulose
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high production cost of cyclodextrins is a significant barrier due to the high cost of the cyclodextrin glycosyltransferase (CGTase) enzyme and the need for downstream purification, while existing methods rely heavily on starch and lack efficient utilization of lignocellulosic wastes.
Innovation Solution
A novel system and method utilizing a tubular membrane bioreactor with a polyethersulfone membrane and hierarchical copper-based metal-organic framework (H-Cu-BTC) for CGTase immobilization, enabling continuous enzymatic hydrolysis of cellulose to glucose, followed by reaction with CGTase to produce cyclodextrins, with integrated ultrafiltration for pure product separation and enzyme reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If free-form CGTase enzyme is used for cyclodextrin production, then the production process is simple, but the production cost is high and enzyme reusability is poor
Solution Approach 1:
The patent employs a two-part system where the first part continuously produces glucose from cellulose, and the second part continuously converts glucose to cyclodextrins using immobilized CGTase. The system is self-sustaining with continuous operation, eliminating batch processing complexities while enabling enzyme reusability and reducing production costs through continuous manufacturing.
Solution Approach 2:
The patent changes the physical state of the CGTase enzyme from free-form to immobilized form on a support matrix. This parameter change enables the enzyme to be retained in the second reactor while allowing continuous flow of substrates and products, achieving both cost efficiency through reusability and process simplicity through continuous operation.
2Productivity
If downstream purification is performed to separate and reuse the enzyme, then enzyme reusability improves, but production cost increases
Solution Approach 1:
The patent extracts the CGTase enzyme from the free-form state and immobilizes it on a solid support matrix in the second reactor. This extraction of the enzyme into a fixed phase allows it to be retained in the reactor while substrates and products flow through, eliminating the need for downstream purification steps and reducing production costs while maintaining high enzyme reusability.
Solution Approach 2:
The solid support matrix acts as an intermediary between the CGTase enzyme and the liquid substrate flow. The matrix provides a surface for enzyme immobilization while allowing continuous passage of glucose and cyclodextrin molecules, enabling enzyme retention without requiring complex purification systems.
3Adaptability or versatility
If starch is used as substrate for cyclodextrin production, then the process is well-established, but lignocellulosic wastes cannot be utilized
Solution Approach 1:
The patent segments the production process into two distinct continuous reactors: the first reactor dedicated to cellulose hydrolysis using cellulase, and the second reactor dedicated to cyclodextrin synthesis using immobilized CGTase. This segmentation allows optimization of each step for its specific substrate, enabling efficient utilization of lignocellulosic wastes while maintaining overall process efficiency.
Solution Approach 2:
The patent creates a universal system that can process cellulose from various lignocellulosic wastes by using cellulase in the first reactor to convert different cellulose sources into glucose, which then serves as a universal substrate for the CGTase enzyme in the second reactor. This multi-functional approach enables versatility in substrate utilization while maintaining process efficiency.
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 reduces production costs, enhances enzyme stability and reusability, and ensures high-purity cyclodextrins without additional purification steps, making the process more sustainable and efficient.
Implementation Method 1
The inner reactor is designed for the addition of enzymes, substrates and lignocellulosic wastes, and comprises a polyethersulfone membrane
Implementation Method 2
hierarchical copper-based metal-organic framework (H-Cu-BTC) for CGTase immobilization
Implementation Method 3
continuous enzymatic hydrolysis of cellulose to glucose
Implementation Method 4
reaction with CGTase to produce cyclodextrins
Data Source
AI summary
The present invention pertains to novel system and methods for the streamlined and efficient continuous production of cyclodextrins by utilizing lignocellulosic wastes. The system comprises a tubular membrane bioreactor where enzymatic hydrolysis of cellulose into glucose is conducted continuously. The method comprises a first part where cellulose is hydrolyzed to pure glucose and a second part where the pure glucose reacts with to CGTase enzyme to obtain pure cyclodextrins.