Vertical Plug-Flow Fermentation for Ethanol Recovery
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Solution Overview
Problem
Current methods for producing crude bio ethanol and solid transformation products face challenges in achieving uniform plug-flow conditions and efficient ethanol recovery due to issues with transportation by gravitational force in vertical, non-agitated reactors, leading to uneven retention times and reduced ethanol yield.
Innovation Solution
A continuous plug-flow process in a vertical, non-agitated, closed tank with controlled water content and bulk density ratio, utilizing gravitational force for transportation, ensures uniform plug-flow and high ethanol recovery by maintaining the wet bulk density to dry bulk density ratio between 0.60 to 1.45, preventing compaction and maintaining free-flowing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the substrate is incubated in a vertical, non-agitated reactor using gravitational force for transportation, then the reactor design is simpler and operational costs are reduced, but the plug-flow conditions become uneven and retention times vary, reducing ethanol yield
Solution Approach 1:
The patent applies parameter changes by optimizing the substrate's bulk density ratio (wet bulk density to dry bulk density between 0.60-1.45) and water content (35-70% by weight). These parameter adjustments ensure the substrate maintains free-flowing characteristics during gravitational transport in the vertical reactor, achieving uniform plug-flow conditions and consistent retention times while preserving the simple reactor design and high ethanol yield
2Ease of operation
If water content is increased to maintain substrate flowability, then gravitational transportation is improved, but substrate compaction occurs, disrupting uniform plug-flow and increasing retention time variability
Solution Approach 1:
The patent resolves this contradiction by precisely controlling the water content (35-70% by weight) and bulk density ratio (0.60-1.45) parameters. This optimization ensures the substrate remains free-flowing for easy gravitational transportation while preventing compaction that would disrupt plug-flow uniformity, thereby maintaining both ease of operation and flow stability
3Device complexity
If batch processes are used for solid substrate fermentation, then process control is simpler, but productivity is lower compared to continuous processes
Solution Approach 1:
The patent implements continuous solid substrate fermentation, allowing the useful action of fermentation to proceed continuously without batch interruptions. The vertically oriented reactor with gravitational flow enables continuous substrate movement and product removal, significantly improving productivity while maintaining relatively simple process control through the natural flow dynamics
4Stability of the object's composition
If stirring means are used to maintain substrate homogeneity, then mixing efficiency is improved, but device complexity and operational costs increase
Solution Approach 1:
The patent employs a self-service approach where the substrate's own gravitational flow and the vertical reactor configuration naturally maintain substrate homogeneity and plug-flow conditions. No external stirring or mixing equipment is required, as the system uses the substrate's inherent properties and gravitational force to achieve uniform flow and mixing, thereby eliminating complex mixing equipment while maintaining substrate homogeneity
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 achieves over 98% recovery of crude ethanol and produces a solid transformation product with 25-90% protein content, suitable for food, feed, or pharmaceutical use, while reducing operational costs and maintaining uniform processing times.
Implementation Method 1
a continuous plug-flow process in a vertical, non-agitated, closed tank where the transport is mediated by gravitational force
Implementation Method 2
mixing said substrate with live yeast... incubating said mixture for 1-48 hours at a temperature of about 20-60 °C... simultaneous production of crude ethanol and a solid transformation product
Data Source
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AI summary
The invention relates to a method for the simultaneous production of a solid transformation product of the substrate and crude ethanol comprising the following steps: • preparing a substrate from milled or flaked biomass comprising proteinaceous matter which originates from soya bean, rape seed, or mixtures thereof, optionally in further mixture with proteinaceous matter originating from fava beans, peas, sunflower seeds, lupine, cereals, and/or grasses, • mixing said substrate with live yeast in a dry matter ratio of from 1:1 to 10,000:1 and adding water in an amount which provides a ratio of wet bulk density to dry bulk density from 0.60 to 1.45 in the resulting mixture; • incubating said mixture for 1-48 hours at a temperature of about 20-60 °C; and • separating crude ethanol and wet solid transformation product from said mixture; further comprising that the incubation is performed as a continuous plug-flow process in a vertical, non-agitated, closed incubation tank with inlet means for said mixture and additives and outlet means for the solid transformation product and crude ethanol. The invention further relates to the products of this method as well as uses thereof.