Control of bioreactor processes

Patent metadata

Field	Value
Publication number	US-2016010116-A1
Application number	US-201414329881-A
Country	US
Kind code	A1
Filing date	Jul 11, 2014
Priority date	Jul 11, 2014
Publication date	Jan 14, 2016
Grant date	—

Abstract

Processes, as well as associated systems and computer program (software) products, are disclosed for the biological conversion of CO into desired end products such as ethanol. The control methodologies used for these processes can advantageously result in a reduced time required for a batch operation or other initial operating period, prior to achieving a continuous operation, which may be demarcated either by the addition of fresh culture medium at a defined flow rate or by another process initiation target. The control methodologies may alternatively, or in combination, improve a process performance parameter, such as productivity of the desired end product or bacterial growth rate, during this batch operation or other initial operating period.

First claim

1 . A process for initiating and carrying out the conversion of CO into an end product, the process comprising:
feeding both a CO-containing substrate and a basic neutralizing agent to a bioreactor comprising a culture medium containing carboxydotrophic bacteria to generate the end product and an acidic metabolite, wherein a basic neutralizing agent flow rate is controlled based on a property of the culture medium, the property selected from the group consisting of an acidic metabolite measured concentration, an acidic metabolite measured productivity, a carboxydotrophic bacteria measured concentration, a carboxydotrophic bacteria measured productivity, or a combination thereof.

2 . The process of claim 1 , wherein the basic neutralizing agent flow rate is controlled based on the acidic metabolite measured concentration in the culture medium or the acidic metabolite measured productivity in the culture medium.

3 . The process of claim 2 , wherein the basic neutralizing agent flow rate is controlled based on the acidic metabolite measured concentration in the culture medium.

4 . The process of claim 3 , wherein the acidic metabolite measured concentration is determined intermittently or continuously during the batch operation period.

5 . The process of claim 3 , wherein the basic neutralizing agent flow rate is controlled based on a difference between the acidic metabolite measured concentration in the culture medium and an acidic metabolite set point concentration in the culture medium.

6 . The process of claim 5 , wherein the acidic metabolite set point concentration is determined according to a formula:
A 1 ·BIOCONmv+B 1
wherein BIOCONmv represents a carboxydotrophic bacteria measured concentration in the culture medium, and A 1 and B 1 are constants.

7 . The process of claim 6 , wherein the constants A and B are determined empirically from experimental data.

8 . The process of claim 6 , wherein the carboxydotrophic bacteria measured concentration is determined intermittently or continuously.

9 . The process of claim 3 , wherein a diluent flow rate to the bioreactor is controlled based on a carboxydotrophic bacteria measured concentration in the culture medium.

10 . The process of claim 9 , wherein a diluent flow rate set point is determined according to a formula:
C 1 (BIOCONmv) wherein BIOCONmv represents a carboxydotrophic bacteria measured concentration in the culture medium, and wherein C 1 is a constant determined empirically from experimental data.

11 . The process of claim 1 , wherein a CO-containing substrate flow rate is controlled based on a measured pH value of the culture medium.

12 . A process for initiating and carrying out the conversion of CO into an end product, the process comprising:
feeding both a CO-containing substrate and a basic neutralizing agent to a bioreactor containing carboxydotrophic bacteria, wherein a basic neutralizing agent flow rate is controlled based on a CO-containing substrate measured flow rate or a CO-containing substrate flow rate set point.

13 . The process of claim 12 , wherein a basic neutralizing agent flow rate set point varies linearly with the CO-containing substrate measured flow rate or the CO-containing substrate flow rate set point.

14 . The process of claim 13 , wherein the basic neutralizing agent flow rate set point is determined according to a formula:
Y·COFLOmv+Z or Y·COFLOsp+Z, wherein COFLOmv and COFLOsp represent, respectively, the CO-containing substrate measured flow rate and the CO-containing substrate flow rate set point, and wherein Y and Z are constants determined empirically from experimental data.

15 . The process of claim 12 , wherein the basic neutralizing agent flow rate is controlled based on the CO-containing substrate flow rate set point.

16 . The process of claim 15 , wherein the CO-containing substrate flow rate set point is determined from a measured pH value of a culture medium contained in the bioreactor.

17 . The process of claim 12 , wherein the basic neutralizing agent flow rate is controlled based on the CO-containing substrate measured flow rate.

18 . The process of claim 1 wherein the process is performed during a batch operation period.

19 . The process of claim 18 , further comprising, after attaining a continuous process initiation target, adding fresh culture medium to the bioreactor and withdrawing the end product from the bioreactor.

20 . The process of claim 1 wherein the CO-containing substrate is obtained from an industrial process selected from the group consisting of a steel manufacturing process, a non-ferrous product manufacturing process, a petroleum refining process, a biofuel production process, a coal gasification process, an electric power production process, a carbon black production process, an ammonia production process, a methanol production process, gasification of organic matter, steam reforming of hydrocarbons and a coke manufacturing process.

21 . The process of claim 1 , wherein the acidic metabolite is acetic acid.

22 . The process of claim 1 wherein the end product is ethanol.

23 . The process of claim 1 wherein the basic neutralizing agent is ammonium hydroxide solution.

Assignees

• Lanzatech New Zealand Ltd

Inventors

• Collet Christophe
• Waters Guy William
• Bromley Jason Carl
• Yang Justin Yi
• Wilson Jarod Nathan

Classifications

• C12M41/48

  Automatic or computerized control (automatic analysis G01N35/00) · CPC title

• C12M21/12 Primary

  for producing fuels or solvents (C12M21/04 takes precedence; liquid carbonaceous fuels C10L1/00, solid fuels C10L5/00) · CPC title

• C12P7/065 Primary

  with microorganisms other than yeasts · CPC title

• G16B99/00

  Subject matter not provided for in other groups of this subclass · CPC title

• C12M41/00

  Means for regulation, monitoring, measurement or control, e.g. flow regulation (controlling or regulating chemical, physical or physicochemical processes B01J19/0006; heating or cooling apparatus for laboratory use B01L7/00; electro optical investigation of individual particles, flow cytometers G01N15/14; automatic analysis G01N35/00; controlling or regulating in general G06N) · CPC title