Two-Stage Fermentation for Biofuel Yield
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Solution Overview
Problem
Current biofuel production processes face challenges such as low yield and high costs due to the inefficiency in converting non-edible plant parts, like cellulose and hemicellulose, into fuel, and the venting of carbon dioxide during fermentation, which reduces greenhouse gas emission benefits.
Innovation Solution
A process involving two fermentations: one for gases like CO, CO2, and H2, and another for carbohydrates, where an aqueous stream from the gas fermentation is introduced into the carbohydrate fermentation to increase product concentration and reduce recovery costs, utilizing biogenic gases and carbohydrates to enhance biofuel yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If carbon dioxide is vented during fermentation, then the fermentation process is simple, but the greenhouse gas emission benefits are reduced
Solution Approach 1:
The patent captures and recovers carbon dioxide that would otherwise be vented during fermentation. The captured CO2 is then utilized as a substrate in gas fermentation processes to produce additional fuel, transforming a waste stream into a valuable resource and maintaining greenhouse gas emission benefits.
Solution Approach 2:
The patent introduces an intermediary carbon capture and utilization system between the carbohydrate fermentation and the environment. The captured CO2 serves as an intermediary substrate that connects the two fermentation processes, allowing the CO2 to be converted into useful fuel products rather than being released.
2Ease of manufacture
If only carbohydrate fermentation is used, then the process is simple, but the fuel yield is low
Solution Approach 1:
The patent merges carbohydrate fermentation with gas fermentation in an integrated two-stage process. The gas fermentation stage uses captured CO2 and hydrogen to produce additional fuel, combining the outputs of both fermentation processes to achieve higher overall fuel yields from the same feedstock.
Solution Approach 2:
The patent creates a continuous cycle where CO2 produced during carbohydrate fermentation is immediately captured and fed into gas fermentation. This continuous utilization of CO2 as a substrate maintains productive action throughout the system, maximizing fuel production from the original carbohydrate feedstock.
3Quantity of substance
If non-edible plant parts are used, then the feedstock availability increases, but the conversion efficiency is low
Solution Approach 1:
The patent changes the fermentation parameters and microorganism types to optimize conversion of recalcitrant plant materials. By using specialized gas-fermenting microorganisms and optimizing conditions for cellulose and hemicellulose degradation, the system achieves efficient conversion of non-edible plant parts into fuel.
Solution Approach 2:
The patent segments the conversion process into distinct stages: pretreatment of plant material, carbohydrate fermentation, and gas fermentation. This segmentation allows each stage to be optimized independently, with the gas fermentation stage specifically targeting the efficient conversion of complex plant polymers into fuel products.
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 improves biofuel yield and maintains a beneficial greenhouse gas emission impact by increasing the concentration of fermentation products, reducing recovery costs, and utilizing biogenic carbon dioxide effectively.
Implementation Method 1
The biogenic carbon dioxide and hydrogen are converted to a fuel, a fuel intermediate, or a chemical product by a gas fermentation
Implementation Method 2
a carbohydrate fermentation that includes introducing at least one carbohydrate to a carbohydrate fermentation unit
Data Source
AI summary
A process is provided for forming a fuel or a fuel intermediate from two fermentations that includes feeding an aqueous solution comprising a fermentation product from a first bioreactor to a second bioreactor and/or a stage upstream of the second bioreactor, which also produces the fermentation product. The aqueous solution may be added at any stage of the second fermentation and/or processing steps upstream from the second bioreactor that would otherwise require the addition of water. Accordingly, the product yield is increased while fresh/treated water usage is decreased.