Vacuum Cell Wall Rupture for Organic Material Processing
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Solution Overview
Problem
Conventional organic material pressure treatment methods require large amounts of heat and moisture to generate high pressure, increasing energy consumption and costs, and result in robust and costly equipment, while also needing protection for vacuum pumps from moisture, with a need to recapture heat from vapor streams for efficient processing.
Innovation Solution
Applying a deep vacuum below atmospheric pressure to break cell walls in organic material, using a moisturized organic material processing system where the material is homogenized under vacuum, with a moisture collector to recapture heat from vapor streams and reuse it to preheat water for further processing, reducing energy needs and equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If increased pressure is applied to break cell walls in organic material, then the processable free sugars and surface area increase, but large amounts of heat and moisture are required which increases energy consumption
Solution Approach 1:
Instead of applying pressure to break cell walls, the patent applies vacuum (negative pressure) to achieve the same effect. The vacuum causes moisture within the organic material to vaporize and expand, creating internal pressure that ruptures cell walls from within, thereby inverting the conventional approach of external pressurization and reducing external energy input requirements
Solution Approach 2:
The patent utilizes phase transition of moisture within the organic material. By applying vacuum, the moisture transitions from liquid to vapor phase, expanding in volume and creating internal pressure that breaks cell walls. This phase transition provides the mechanical force needed for cell wall rupture without requiring external high-pressure heating
2Productivity
If increased pressure is applied to break cell walls in organic material, then the processable free sugars and surface area increase, but more robust pressure vessels are required which increases equipment cost
Solution Approach 1:
The patent inverts the pressure approach by using vacuum instead of high pressure. This allows the use of simple atmospheric or near-atmospheric pressure vessels rather than expensive high-pressure autoclaves, dramatically reducing equipment manufacturing costs and complexity while achieving the same cell wall breakdown effect through internal vapor expansion
3Productivity
If vacuum pumps are used to reduce pressure for processing organic material, then cell walls are broken effectively, but moisture must be protected from reaching the vacuum pump which reduces operational efficiency
Solution Approach 1:
The patent extracts or separates the moisture vapor from the vacuum system by using a condenser positioned between the processing chamber and vacuum pump. The condenser captures moisture vapor before it can reach the vacuum pump, protecting the pump from moisture damage while allowing the vacuum system to maintain effective negative pressure for cell wall breakdown
Solution Approach 2:
The condenser acts as an intermediary device between the vacuum processing chamber and the vacuum pump. It mediates the interaction by condensing moisture vapor from the process stream, thereby protecting the vacuum pump from moisture exposure while allowing the vacuum system to function effectively
4Productivity
If heat is added to generate pressure for processing organic material, then cell walls are broken effectively, but the processed material is at elevated temperature requiring cooling which increases energy consumption
Solution Approach 1:
The patent utilizes the phase transition of moisture from liquid to vapor under vacuum to provide the mechanical force for cell wall breakdown, eliminating the need for high-temperature heating. The process occurs at or near ambient temperature, so no cooling energy is required and there is minimal thermal energy loss
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 method effectively increases the availability of processable free sugars and surface area, reduces energy consumption, and lowers equipment costs by using a vacuum system that is less demanding on materials and energy, while efficiently processing organic materials without the need for additional chemicals or additives.
Implementation Method 1
the vacuum applied being sufficiently below atmospheric pressure during that period of time to bring the latent moisture content entrained in the organic material to a vaporization point to create an internal pressure in the moisturized organic material to rupture cell walls
Implementation Method 2
recapture heat from the vapor stream leaving the process vessel to heat the fluid utilized to moisturize the organic material
Implementation Method 3
The moisture collector includes an inlet valve in communication with a collection tank through which the flow stream passes and which includes a heat exchanger and in communication with a condensation accumulator
Data Source
AI summary
Moisturized organic material is treated by communicating with a vacuum pump (44) to selectively reduce pressure within a vessel (12) below atmospheric pressure and to a vaporization point, such as at 30 to 17.8° C., for a period of time sufficient to create an internal pressure to rupture cell walls. While being subjected to vacuum below atmospheric pressure, the vessel (12) is rotated to homogenize the moisturized organic material. The organic material can be moisturized by non-potable water including moisture collected by a moisture collector (44b) in the conduit (44a) between the vessel (12) and the vacuum pump (44) and by chilled feed water acting as the seal fluid in the vacuum pump and heated while flowing through a heat exchanger (148) of the moisture collector (44b). Heat can be added by a heater (46) to raise the temperature of low ambient temperature moisturized organic material.