Vertical Non-Agitated Tank for Bio-Conversion
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Solution Overview
Problem
Existing bio-conversion methods for producing valuable solid transformation products from biomass substrates face challenges in achieving uniform plug-flow and efficient bio-conversion, particularly due to issues with transportation by gravitational force and optimal water content management.
Innovation Solution
The method employs a vertical, non-agitated tank for bio-conversion, where the flow of material is regulated to maintain uniform plug-flow conditions. The water content is balanced to ensure sufficient water activity, with a wet bulk density to dry bulk density ratio maintained between 0.60 and 1.45, preventing compaction and sedimentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If batch processes are performed on flatbeds without stirring, then operational complexity is reduced, but productivity and bio-conversion efficiency are limited
Solution Approach 1:
The patent inverts the conventional horizontal flatbed batch process into a vertical continuous flow process. Material is fed from the top and flows downward through the reactor under gravity, enabling continuous processing without stirring mechanisms while maintaining high bio-conversion efficiency through controlled residence time and uniform flow distribution.
Solution Approach 2:
The invention transitions from discontinuous batch processing to continuous flow processing. The reactor operates continuously with material flowing through the system, allowing uninterrupted bio-conversion and eliminating the idle time between batches, thereby significantly improving productivity.
2Reliability
If water content is increased to maintain water activity, then microorganism activity is improved, but substrate compaction and sedimentation occur
Solution Approach 1:
The patent optimizes the water content parameter to a specific range (40-60% of substrate weight) that balances microorganism activity requirements with substrate structure stability. This parameter optimization ensures sufficient water activity for microbial metabolism while preventing excessive compaction and sedimentation that would occur at higher water contents.
Solution Approach 2:
The continuous flow system dynamically adjusts substrate movement and residence time, preventing static compaction that occurs in batch processes. The constant flow maintains substrate porosity and structure while providing adequate moisture for microbial activity.
3Device complexity
If gravitational force is used for material transport, then device complexity is reduced, but uniform plug-flow conditions are difficult to achieve
Solution Approach 1:
The patent transitions from horizontal to vertical reactor orientation, utilizing the vertical dimension for gravity-driven flow. This dimensional change enables uniform plug-flow conditions by ensuring consistent downward movement of material through the reactor, achieving both simple gravity-based transport and precise flow control.
Solution Approach 2:
The invention replaces mechanical stirring and pumping systems with gravity-driven flow. Material is fed from the top and moves downward through the reactor under gravity alone, eliminating complex mechanical transport mechanisms while achieving uniform flow distribution and eliminating the need for stirring devices.
4Productivity
If continuous SSF processes are performed in stirred tank reactors, then productivity is improved, but device complexity and operational costs increase
Solution Approach 1:
The patent extracts and removes the stirring mechanism from the continuous SSF reactor, demonstrating that effective continuous processing can be achieved without mechanical agitation. The system relies on gravity-driven flow and proper substrate preparation to maintain uniform processing, eliminating the complexity and cost of stirring devices while preserving high productivity.
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 allows for efficient and fast bio-conversion of biomass, such as soya bean or rape seed, into valuable products like organic acids and alcohols, while reducing operational costs and maintaining a simpler reactor design.
Implementation Method 1
a vertical, non-agitated tank where the transport is mediated by gravitational force
Implementation Method 2
microorganism genera which produce one or more organic compounds as metabolic product of carbohydrate bio-conversion
Data Source
AI summary
The invention relates to a method for producing a solid transformation product of a substrate comprising the following steps: • preparing a substrate of biomass comprising carbohydrates and proteinaceous matter that originates from soya bean, rape seed, or mixtures thereof, optionally in further mixture with carbohydrates and proteinaceous matter originating from fava beans, peas, sunflower seeds, lupine, cereals, and/or grasses, • mixing said substrate with a live microorganism or a combination of live microorganisms, which live microorganism or mixture of live microorganisms is not live yeast, and adding water in an amount which provides an initial incubation mixture having a water content from 30 to 70 % by weight, and a ratio of wet bulk density to dry bulk density from 0.60 to 1.45 in the resulting mixture; • incubating said initial incubation mixture for 1-240 hours at a temperature of 15-70°C; and thereafter recovering wet solid transformation product from the incubation mixture; further comprising that the incubating step is performed as a continuous plug-flow process in a vertical, non-agitated incubation tank with inlet means for said mixture and additives and outlet means for said solid transformation product.