Continuous Vanillin Fermentation Extraction Process

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Solution Overview

Problem

Current bioconversion processes for vanillin production face challenges due to vanillin toxicity on microorganisms, leading to limited productivity and selectivity, as the compound tends to degrade into byproducts like vanillin alcohol and vanillic acid, and existing coupling processes with extraction do not fully address this issue.

Innovation Solution

A process involving continuous substrate addition and simultaneous extraction of fermentation broth through a separating device to maintain low vanillin concentrations, reducing residence time and recycling microorganism-containing broth to promote bioconversion, using techniques like membrane filtration or liquid-liquid extraction to selectively recover vanillin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If vanillin is produced by bioconversion in a fermenter, then vanillin is obtained as a product, but vanillin toxicity limits productivity and causes degradation into byproducts

Engineering Contradiction:

Improvevanillin production rateVSAvoidvanillin toxicity on microorganisms

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies extraction principles by continuously removing vanillin from the fermentation broth using a separating device. This extraction process reduces the vanillin concentration in the fermenter, thereby decreasing its toxic effect on microorganisms and preventing degradation into byproducts, while maintaining continuous production.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent implements continuous operation by continuously adding substrate to the fermenter and continuously extracting vanillin through a separating device. This continuous action maintains optimal conditions for bioconversion throughout the process, preventing accumulation of toxic vanillin and sustaining high productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If vanillin concentration is increased to improve productivity, then more product is formed, but selectivity decreases due to transformation into degradation products

Engineering Contradiction:

Improvevanillin yieldVSAvoidselectivity for vanillin

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The separating device continuously extracts vanillin from the fermentation broth, maintaining low vanillin concentration in the fermenter. This prevents the transformation of vanillin into degradation products like vanillin alcohol and vanillic acid, thereby maintaining high selectivity while achieving improved productivity through continuous production.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If a conventional coupling process with extraction is used, then vanillin is separated from the fermenter, but vanillin remains in high amount causing continued toxicity

Engineering Contradiction:

Improvevanillin toxicityVSAvoidbioconversion efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent employs continuous extraction rather than batch extraction. The separating device operates continuously to remove vanillin from the fermentation broth, ensuring that vanillin concentration remains consistently low throughout the process. This continuous removal prevents toxicity-related inhibition of bioconversion, maintaining high productivity.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system implements a feedback mechanism where the separating device continuously monitors and removes vanillin based on its concentration in the fermentation broth. This feedback control ensures that vanillin concentration remains below toxic levels, preventing inhibition of the microorganisms and maintaining optimal bioconversion efficiency.

Inventive Principle:

Principle #23Feedback

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 effectively reduces vanillin toxicity, increases productivity, and enhances selectivity by continuously removing vanillin from the fermenter, allowing for improved bioconversion and maintaining vanillin concentration below toxic levels for microorganisms.

Implementation Method 1

through a separating device whereby are provided (i) a fermentation broth composition (a) devoid from said microorganism and (ii) a fermentation broth composition (b) comprising said microorganism

Methodology Applied

Scientific EffectMembrane filtration: Semipermeable Membrane

Implementation Method 2

using techniques like membrane filtration or liquid-liquid extraction to selectively recover vanillin

Methodology Applied

Scientific EffectLiquid-liquid extraction: Liquid-Liquid Extraction

Implementation Method 3

cultivating in a fermenter at least one microorganism able to form vanillin by bioconversion of a substrate

Methodology Applied

Scientific EffectBioconversion: Fermentation

Data Source

PatentUS11060118B2Production of vanillin by fermentation

Publication Date: 2021.07.13 SPECIALTY OPERATIONS FRANCE

AI summary

The present invention relates to a new process of vanillin production from a substrate by bioconversion and that allows a continuously producing and removing vanillin from the fermentation broth as it is formed. In particular, the invented process advantageously allows to reduce the residence time of vanillin in the fermenter and to maintain the vanillin concentration, in the fermentation broth, below its toxic level for the microorganism.