Microbial Cellulose Production from Waste Textiles
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Solution Overview
Problem
Current processes for producing microbial cellulose from waste textiles are inefficient due to cellulose dissolution and partial degradation of non-cellulosic fibers, leading to reduced enzymatic conversion efficiency, high energy consumption, and increased costs.
Innovation Solution
A process involving pre-treatment with an aqueous solution of NaOH and urea at controlled temperatures to minimize cellulose dissolution and fiber degradation, followed by enzymatic saccharification, which allows for effective conversion of cellulose to glucose without requiring regeneration of cellulose and reduces energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-treatment with ionic liquids or strong acids is used to process waste textiles, then cellulose can be dissolved and regenerated, but cellulose dissolution occurs and enzymatic conversion efficiency is reduced
Solution Approach 1:
The patent changes the chemical parameters of pre-treatment by using aqueous NaOH solutions at controlled concentrations (1-10% w/v) and temperatures (20-50°C) instead of ionic liquids or strong acids. This parameter change achieves effective cellulose processing while preserving cellulose integrity and maintaining high enzymatic conversion efficiency, resolving the contradiction between ease of manufacture and productivity
Solution Approach 2:
The patent employs inexpensive, readily available reagents (NaOH, urea, H2O2) for pre-treatment instead of costly ionic liquids that require regeneration. These simple chemical agents effectively process the textile waste without causing cellulose dissolution, thereby maintaining enzymatic conversion efficiency while reducing both cost and complexity
2Productivity
If high temperature treatment is applied to hydrolyze cellulose, then conversion speed increases, but energy consumption increases
Solution Approach 1:
The patent replaces thermal energy input with enzymatic catalysis for cellulose hydrolysis. Instead of using high-temperature mechanical/thermal hydrolysis, the invention employs cellulase enzymes that catalyze the breakdown of cellulose to glucose at moderate temperatures (30-50°C), thereby maintaining high conversion speed while dramatically reducing energy consumption
Solution Approach 2:
The patent changes the operational parameters from high-temperature thermal processing to moderate-temperature enzymatic processing. By controlling temperature in the range of 30-50°C during enzymatic hydrolysis, the system achieves effective conversion speed without the high energy consumption associated with high-temperature treatment
3Productivity
If conventional pre-treatment methods are used on blend textiles, then cellulose can be accessed, but non-cellulosic fibers are degraded
Solution Approach 1:
The patent uses controlled parameters for chemical pre-treatment: dilute NaOH solutions (1-10% w/v) at moderate temperatures (20-50°C) with limited treatment time. These controlled parameters selectively access cellulose fibers for enzymatic conversion while minimizing damage to non-cellulosic fibers, thereby maintaining both cellulose accessibility and fiber integrity
Solution Approach 2:
The pre-treatment process applies different chemical environments to different fiber types within the blend. The controlled NaOH treatment selectively targets and opens up cellulose fiber structures for enzyme access while leaving non-cellulosic fibers relatively unaffected, achieving local quality differentiation that preserves overall fiber integrity
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 process enhances the yield of glucose production, minimizes fiber degradation, and reduces overall costs, making it suitable for industrial-scale application while maintaining the integrity of synthetic fibers for recycling.
Implementation Method 1
pre-treating said waste textile material with an aqueous solution comprising a base, preferably NaOH, and an amide, preferably urea, to obtain a pre-treated textile material
Implementation Method 2
treating said pre-treated textile material with cellulase, to convert said cellulose into glucose
Implementation Method 3
treating said pre-treated textile material with cellulase, to convert said cellulose into glucose
Implementation Method 4
treating said pre-treated textile material with cellulase, to convert said cellulose into glucose
Implementation Method 5
preparing a microbial culture using said liquid phase mixture including glucose, wherein said microbial culture comprises microbial cellulose-producing microorganisms; and incubating said microbial culture to obtain microbial cellulose
Data Source
AI summary
The present invention refer to a process for the production of microbial cellulose using a waste textile material, for example 100% cotton or blended cotton/polyester/elastane waste textile, said waste textile material comprising cellulose, comprising the following steps: providing an amount of said waste textile material; pre-treating said waste textile material with an aqueous solution comprising NaOH and urea, to obtain a pre-treated fabric, wherein said step of treating said waste textile with an aqueous solution comprising NaOH and urea is carried out at a temperature ranging from −25° C. to +30° C.; treating said pre-treated fabric with cellulase enzymes, to convert said cellulose into glucose, whereby a mixture including glucose is obtained; preparing a culture medium comprising said mixture including glucose; inoculating said culture medium with microbial cellulose producing microorganisms; and incubating said microbial cellulose producing microorganisms to obtain microbial cellulose.