Vacuum Vaporization and Absorption for Butanol Recovery
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Solution Overview
Problem
Current methods for removing butanol from fermentation broths face challenges such as high costs due to cooling requirements and inefficiencies in processing low-pressure vapor streams, particularly in maintaining butanol levels below microbial tolerance thresholds without limiting sugar loadings, and dealing with residual CO2 in the gas stream.
Innovation Solution
The process involves partial vaporization of the fermentation liquid under vacuum to produce a vapor stream enriched in butanol, which is then contacted with an absorption liquid, allowing for efficient absorption and regeneration of the product alcohol, while also managing CO2 absorption and reducing the need for cooling through heat integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If butanol is removed from fermentation broth to maintain levels below microbial tolerance thresholds, then productivity is improved, but the cost of cooling and processing vapor streams increases
Solution Approach 1:
The patent utilizes vacuum vaporization to transition butanol from liquid to vapor phase for separation, then employs condensation to transition the vapor back to liquid form for collection. This phase transition approach enables efficient product recovery without requiring extensive cooling of large vapor volumes, thereby reducing energy loss while maintaining high productivity
Solution Approach 2:
The patent changes the pressure parameter by operating under vacuum conditions during vaporization, which lowers the boiling point of butanol and enables separation at reduced temperatures. This parameter change reduces the thermal energy required for the process and minimizes cooling costs while maintaining effective product removal
2Productivity
If high sugar loadings are charged to fermentation vessels, then productivity is improved, but butanol tolerance levels are exceeded causing production rate to fall
Solution Approach 1:
The patent implements preliminary action by continuously removing butanol from the fermentation broth during the fermentation process itself, rather than waiting for accumulation. This proactive removal prevents butanol from reaching toxic levels that would inhibit microbial activity, enabling high sugar loadings to be processed efficiently throughout the entire fermentation cycle
Solution Approach 2:
The patent establishes continuity of useful action by implementing continuous in-situ product removal during fermentation. The vaporization and condensation system operates continuously to maintain butanol concentrations below inhibitory thresholds, allowing the fermentation process to proceed at high productivity without interruption from toxicity effects
3Manufacturing precision
If vacuum vaporization is used to remove butanol, then manufacturing precision is improved, but the complexity of processing the resulting low-pressure vapor stream increases
Solution Approach 1:
The patent applies the extraction principle by separating butanol from the fermentation broth through vacuum vaporization, extracting the product in vapor form. The condensed butanol is then taken out from the vapor stream and collected separately, simplifying the overall processing system by focusing on selective product extraction rather than complex multi-stage separation
Solution Approach 2:
The patent uses condensation as an intermediary step between vaporization and product collection. The condensation process serves as a mediator that transforms the low-pressure vapor stream into liquid form, making it easier to handle and collect while maintaining the precision benefits of vacuum vaporization without requiring complex direct handling of vapor streams
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 maintains butanol levels below toxic thresholds, allows for high sugar loadings, and reduces energy costs by utilizing absorption liquids like ethylene glycol and amines to absorb butanol and CO2, thereby improving process efficiency and product recovery.
Implementation Method 1
a fermentation liquid feed comprising water and a product alcohol and optionally CO2 is at least partially vaporized such that a vapor stream is produced
Implementation Method 2
Process to remove product alcohol from a fermentation by vaporization under vacuum
Implementation Method 3
the vapor stream containing the product alcohol is contacted with an absorption liquid under suitable conditions wherein an amount of the product alcohol is absorbed
Data Source
AI summary
A fermentation liquid feed including water and a product alcohol and optionally CO2 is at least partially vaporized such that a vapor stream is produced. The vapor stream is contacted with an absorption liquid under suitable conditions wherein an amount of the product alcohol is absorbed. The portion of the vapor stream that is absorbed can include an amount of each of the water, the product alcohol and optionally the CO2. The temperature at the onset of the absorption of the vapor stream into the absorption liquid can be greater than the temperature at the onset of condensation of the vapor stream in the absence of the absorption liquid. The product alcohol can be separated from the absorption liquid whereby the absorption liquid is regenerated. The absorption liquid can include a water soluble organic molecule such as an amine.