U-Loop Fermenter Pressure Zoning for Gas Mass Transfer
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Solution Overview
Problem
Conventional fermentation processes face inefficiencies in mass transfer of gaseous substrates into the liquid phase, leading to reduced productivity and high energy consumption, particularly in processes involving methanotrophic bacteria, due to poor gas utilization and separation in traditional fermenters.
Innovation Solution
The U-shape and/or nozzle U-loop fermenter design with pressure controlling devices in different zones allows for optimized gas transfer by increasing pressure in specific zones to enhance solubility and mass transfer, while reducing pressure elsewhere to facilitate gas release, along with gas flushing mechanisms to improve waste gas removal and prevent explosive mixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stirring tanks with compressed air injection are used, then gas mixing is achieved, but energy consumption is excessive and mass transfer efficiency is insufficient
Solution Approach 1:
The fermenter is divided into multiple vertical zones (aeration zone, separation zone, downward flow zone) with distinct functions. Gas injection occurs at specific locations rather than throughout the entire tank, segmenting the mass transfer process to improve efficiency while reducing overall energy requirements.
Solution Approach 2:
Different zones within the fermenter have different pressure conditions optimized for their specific functions. The aeration zone operates under higher pressure to enhance gas solubility and mass transfer, while other zones operate at lower pressures, creating local quality variations that improve overall process efficiency and reduce energy consumption.
2Productivity
If high pressure is applied throughout the fermenter to improve gas solubility, then mass transfer improves, but waste gas removal becomes difficult and energy consumption increases
Solution Approach 1:
The fermenter is divided into multiple vertical zones (aeration zone, separation zone, downward flow zone) with distinct functions. Gas injection occurs at specific locations rather than throughout the entire tank, segmenting the mass transfer process to improve efficiency while reducing overall energy requirements.
Solution Approach 2:
Different zones within the fermenter have different pressure conditions optimized for their specific functions. The aeration zone operates under higher pressure to enhance gas solubility and mass transfer, while other zones operate at lower pressures, creating local quality variations that improve overall process efficiency and reduce energy consumption.
3Productivity
If high pressure is used to improve mass transfer, then gas dissolution improves, but the risk of explosive gas mixtures in the headspace increases
Solution Approach 1:
Different zones within the fermenter have different pressure conditions optimized for their specific functions. The aeration zone operates under higher pressure to enhance gas solubility and mass transfer, while other zones operate at lower pressures, creating local quality variations that improve overall process efficiency and reduce energy consumption.
Solution Approach 2:
The system converts the potential harm of high pressure (explosive risk) into a benefit by spatially separating high-pressure and low-pressure zones. The high-pressure zone enhances mass transfer while the low-pressure zone safely manages gas removal, transforming the hazard into a controlled process feature.
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 significantly improves the mass transfer and utilization of gaseous substrates, reduces energy consumption, and enhances the productivity of fermentation processes by optimizing gas solubility and separation, making it suitable for continuous operation and cost-effective production of single cell protein.
Implementation Method 1
controlling the pressure differently in the circulating fermentation liquid in at least two different zones in the fermenter by increasing the pressure in at least a first zone of the U-part in the fermenter in relation to the pressure in another zone
Implementation Method 2
thereby increasing the mass transfer of the at least one added gaseous substrate component from the gas phase into the liquid phase in that zone
Implementation Method 3
followed by reducing the pressure in relation to the pressure in the first zone of the U-part, in the circulating fermentation liquid before it enters another zone
Implementation Method 4
whereby the circulating fermentation liquid is circulated in the fermenter by the liquid circulation means
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A fermenter and a method of fermentation in a U-shape and/or nozzle U-loop fermenter (100) comprising a U-part having an essentially vertical down-flow part (101), an essentially vertical up-flow part (102) and a substantially horizontal connecting part (103), which connects the lower ends of the down-flow part (101) and the up-flow part (102), a top part (104) which is provided above the U-part and has a diameter which is substantially larger than the diameter of U-part, means for creating liquid circulation in U-part of the fermenter, and one or more gas injection points (110) for the introduction and dispersion of the gas(ses) into the fermentation liquid. The pressure may be controlled differently in certain zones of the fermenter by pressure controlling devices (105,106,108) e.g. by increasing the pressure in certain zones of the fermenter in relation to the pressure in other zones of the fermenter, or decreasing the pressure in a zone of the fermenter in relation to the pressure in another zone of the fermenter.