WO2010056461A2 - Systèmes de réacteur à cuve verticale - Google Patents

Systèmes de réacteur à cuve verticale Download PDF

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Publication number
WO2010056461A2
WO2010056461A2 PCT/US2009/060804 US2009060804W WO2010056461A2 WO 2010056461 A2 WO2010056461 A2 WO 2010056461A2 US 2009060804 W US2009060804 W US 2009060804W WO 2010056461 A2 WO2010056461 A2 WO 2010056461A2
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WIPO (PCT)
Prior art keywords
reactor
gas
flow zone
reactant
fast
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PCT/US2009/060804
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English (en)
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WO2010056461A3 (fr
Inventor
Jens Wiik Jensen
Eric Dickman
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Uni-Control, Llc
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Publication of WO2010056461A2 publication Critical patent/WO2010056461A2/fr
Publication of WO2010056461A3 publication Critical patent/WO2010056461A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M41/00—Means for regulation, monitoring, measurement or control, e.g. flow regulation
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/04—Bioreactors or fermenters specially adapted for specific uses for producing gas, e.g. biogas
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M27/00—Means for mixing, agitating or circulating fluids in the vessel
    • C12M27/18—Flow directing inserts
    • C12M27/20—Baffles; Ribs; Ribbons; Auger vanes
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M29/00—Means for introduction, extraction or recirculation of materials, e.g. pumps
    • C12M29/06—Nozzles; Sprayers; Spargers; Diffusers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel

Definitions

  • This invention generally relates to vertical shaft reactor systems for carrying out a chemical or biological reaction, and relates more specifically to such reactor systems for producing renewable energy.
  • reactors Long vertical shaft reactors, in-ground, above-ground, or partially in-ground, are well known for carrying out such biological processes as the treatment of wastewater and solid waste suspensions.
  • Such reactors generally include a circulatory system comprising at least two substantially vertical chambers in fluid communication with each other at their upper and lower ends. The lower ends are usually in direct fluid communication, while the upper ends are typically in communication through a basin at the top of the reactor.
  • a circulating fluid, containing soluble and/or suspended reactants, are caused to descend one chamber, usually referred to as a downcomer. From the lower end of the downcomer, the circulating fluid ascends the other chamber, usually referred to as a riser.
  • fluid is driven through the system by the injection at depth of gas, e.g. reactant, into one or both of the chambers.
  • gas e.g. reactant
  • the gaseous reactant is injected into the riser only where it acts as a gas-lift pump, causing the liquid/gas mixture to ascend upwards in the riser.
  • injection of gas may be into the downcomer only. With fluid continually flowing into the downcomer, the fluid/air mixture in the downcomer will have a higher density than the liquid/gas mixture in the riser, thus providing sufficient downward force in the downcomer to maintain circulation.
  • a portion of the suspension is drawn off, for example from the basin at a position adjacent to the upper end of the riser, and the remainder traverses the basin before reentering the downcomer.
  • the injected gas remains in the suspension within regions of greater hydrostatic pressure in the reactor.
  • the dissolved gas may constitute the principal reactant in the reaction, e.g. degrading of waste by aerobic microorganisms.
  • As the circulating suspension rises in the riser to regions of lower hydrostatic pressure dissolved gas separates, forming bubbles.
  • gas disengagement occurs. Reaction between dissolved gaseous reactant, nutrients and microorganisms takes place during circulation through the downcomer, riser and basin of the reactor.
  • an optimum concentration of available dissolved reactant may be required, such that maximum microorganism conversion of gaseous reactant occurs and reactant concentration is not prohibitively toxic to the microorganisms.
  • Gas to liquid transfer occurs mainly as a result of diffusion across the gas-liquid boundary.
  • the mass transfer of gaseous reactant into the circulating suspension may be a major, or rate-limiting, step for the biological or chemical process. Mass transfer of a gaseous reactant is a major concern especially when the gas has low solubility in the suspension medium.
  • vertical shaft reactor systems for carrying out various kinds of chemical or biological reactions that utilize a gaseous reactant. Accordingly, there exists a need for vertical shaft reactor systems designed to provide optimum conversion of gaseous reactant to desired product.
  • a vertical shaft reactor assembly includes a reactor comprising a head including a fluid inlet and an effluent outlet, and an attached shaft.
  • the attached reactor shaft comprises a vertical slow- flow zone having first and second ends, at least a first vertical fast-flow zone adjacent to the slow-flow zone, each the fast flow zone having first and second ends, wherein the first ends are in direct fluid communication and the second ends are in indirect fluid communication through the reactor head.
  • the slow-flow zone, fast-flow zone, and reactor head define a circulation loop.
  • the volume of the slow-flow zone is greater than the fast-flow zone in the reactor.
  • the reactor assembly includes at least a first gas-liquid injection assembly adjacent to and in fluid communication with the fast- flow zone.
  • the gas-liquid injection assembly includes at least one injection nozzle.
  • the injection assembly comprises a nozzle array disposed along at least a portion of the length of the fast- flow zone.
  • a chamber for a radiation source is also included in the assembly, which may be a built-in chamber in the reactor above the reactor head or an external compartment in fluid communication with the vertical shaft reactor.
  • a reactant enrichment chamber is included in the reactor assembly, having at least one outlet and at least one inlet, wherein the reactant enrichment chamber is in fluid communication with the injection assembly via an outlet and a reactant supply source via an inlet.
  • the reactor assembly further comprises a biomass separation unit in fluid communication with the reactor head effluent outlet and the reactant enrichment chamber inlet, wherein separated liquid from the biomass separation unit is mixed with a reactant in the reactant enrichment chamber.
  • the reactor assembly includes a conduit coupled to the reactant enrichment chamber and the slow-flow zone first end, wherein liquid from slow-flow zone is mixed with a reactant in the reactant enrichment chamber.
  • the conduit utilized may further comprise a pump and a venturi.
  • the reactor assembly includes a second vertical fast-flow zone disposed opposite the first fast-flow zone, with the slow-flow zone disposed therebetween.
  • a vertical partition is disposed between the slow-flow zone and each fast-flow zone.
  • a second gas-liquid injection assembly may also be included, which is adjacent to and in fluid communication with the second fast-flow zone and in fluid communication with the reactant enrichment chamber.
  • a reactor system comprising at least one reactor assembly disclosed herein, wherein the first reactor assembly is fluidly connected with the second reactor assembly in series.
  • the depth of at least one reactor assembly in the series is less than the depth of a subsequent reactor assembly in the series.
  • a deep shaft fermentation system comprising: an inlet for feed gas comprising a concentration X 1 of reactant and an outlet for a final fermentation product gas comprising a concentration X n of gaseous reactant; and a number n of deep shaft reactor assemblies aligned in series, wherein each deep shaft reactor assembly comprises: a fermentation feed gas line and a fermentation product gas outlet; a deep shaft fermentation reactor configured for fermentation of a suspension of microorganisms which consume gaseous reactant, wherein the deep shaft reactor is connected with the fermentation product gas outlet and wherein each deep shaft reactor has a depth, a diameter, a normal operating fill line, a reactor inlet for reactant, and a bottom; a biomass extraction unit configured to separate a portion of suspension extracted from the deep shaft reactor into a biomass-reduced fluid comprising a lower concentration of microorganisms than the extracted portion of suspension and a biomass-increased product comprising an increased concentration of microorganisms
  • Each deep shaft reactor may further comprise a riser, a downcomer, and a divider configured such that, during operation, circulation of a suspension comprising microorganisms proceeds up the riser at a first linear velocity, over a top of the divider, and down the downcomer at a second linear velocity, and wherein the divider extends vertically from below the normal operating fill line to above the bottom of the reactor.
  • the first linear velocity is greater than the second linear velocity.
  • the deep shaft reactor assembly may further comprise an effluent recycle line connecting a biomass extraction unit outlet for biomass-reduced fluid with an inlet of the retention chamber.
  • the effluent recycle line fluidly connects the biomass extraction unit outlet for biomass-reduced fluid with the retention chamber inlet fluidly connected to the fermentation feed gas line.
  • the deep shaft reactor may be operable to maintain a headspace above the normal operating fill line and wherein a reactor product gas outlet is located within the headspace.
  • the biomass extraction unit comprises at least one selected from microfiltration modules and ultrafiltration modules.
  • the depth of at least one deep shaft reactor in the series is less than the depth of a subsequent deep shaft reactor in the series.
  • the depth of the i* deep shaft reactor in the series, D 1 is such that the depth of the reactor immediately upstream the i* reactor D 1 . ! is less than D 1 .
  • the depth of the reactors may be selected such that toxicity of the reactant gas to the microorganisms is maintainable below a desired level.
  • each deep shaft reactor assembly is adapted for operation with a fermentation feed gas comprising a concentration X 1 of gaseous reactant and a suspension microorganism concentration M 1 ; wherein the system further comprises measurement apparatus for determining the concentration X f of reactant exiting the last deep shaft reactor assembly of the series, and control equipment whereby the concentration X 1 , the concentration M 1 , or both may be adjusted such that X f remains below a desired value or within a desired range.
  • the system may further comprise a fermentation product gas recycle line fluidly connecting a fermentation product line of at least one deep shaft reactor assembly to a fermentation feed gas line of at least one upstream deep shaft reactor assembly, such that, if X f is undesirably high, the reactant concentration in the feed gas may be reduced.
  • the system may further comprise a feed enhancement line fluidly connecting the fermentation feed gas line of at least one deep shaft reactor assembly to a fermentation feed gas line of at least one downstream deep shaft reactor assembly, whereby X 1 may be maintained as high as possible while maintaining a desired X f .
  • the reactant enhancement line may fluidly connect the inlet to the first deep shaft reactor assembly for feed gas comprising reactant concentration X 1 to a fermentation feed gas line of at least one downstream deep shaft reactor assembly.
  • the reactant in the feed gas may comprise carbon monoxide
  • the system may be configured for production of hydrogen by an aqueous suspension of microorganisms capable of carrying out the water gas shift reaction to convert water and carbon monoxide to hydrogen and carbon dioxide, and the desired concentration X f of gaseous reactant in the fermentation product gas exiting the final deep shaft reactor assembly of the series may be substantially zero.
  • the deep shaft reactor is located at least partially below ground.
  • the reactant in the feed gas comprises carbon monoxide
  • the system is configured for production of hydrogen by an aqueous suspension of microorganisms capable of carrying out the water gas shift reaction to convert water and carbon monoxide to hydrogen and carbon dioxide.
  • a deep shaft fermentation system comprising: an inlet for feed gas comprising a concentration Xi of gaseous reactant and an outlet for a final fermentation product gas comprising a concentration X f of gaseous reactant; a number n of deep shaft fermentation reactors aligned in series and configured for fermentation of a reactant- consuming suspension of microorganisms having a microorganism concentration M 1 , wherein each deep shaft reactor comprises a fermentation feed gas line for a fermentation feed gas having a gaseous reactant concentration X 1 and a fermentation product gas outlet; wherein the first reactor of the series comprises an inlet for the feed gas comprising concentration X 1 of gaseous reactant and the final reactor of the series is connected with the outlet for a final fermentation product gas comprising a concentration X f of gaseous reactant, and wherein each deep shaft reactor has a depth, a diameter, a normal operating fill line, and a bottom; measurement apparatus adapted for determining the concentration X f1 and control
  • the system may further comprise a fermentation product gas recycle line fluidly connecting a fermentation product line of at least one deep shaft reactor to a fermentation feed gas line of at least one upstream deep shaft reactor, such that, if X f is undesirably high, the reactant concentration in the feed gas may be reduced.
  • the system may further comprise a feed enhancement line fluidly connecting the fermentation feed gas line of at least one deep shaft reactor to a fermentation feed gas line of at least one downstream deep shaft reactor, whereby X 1 may be maintained as high as possible while maintaining a desired X f .
  • the depth of at least one deep shaft reactor in the series is less than the depth of a subsequent deep shaft reactor in the series.
  • the depth of the i th deep shaft reactor in the series, D 1 is such that the depth of the reactor immediately upstream the i* reactor, D 1-I , is less than D 1 .
  • the depth of the reactors may be selected such that toxicity of the reactant gas to the microorganisms is below a desired level throughout the system.
  • the system is designed for biological production of fermentation product gas comprising hydrogen via the water-gas shift reaction, wherein the gaseous reactant comprises carbon monoxide.
  • Each reactor of the series may be filled to the normal operating fill line with a suspension of microorganisms.
  • the microorganisms are selected from the group consisting of Rubrivivax gelatinosus, Rhodospirillum rubrum, and Rhodopseudomonas palustris.
  • the microorganisms are capable of aerobically fixing carbon during the oxidation of waste.
  • the microorganisms are capable of fermenting sludge comprising biomass into ethanol, butanol, acetone or a combination thereof.
  • the microorganisms are capable of fermenting gaseous waste products considered green house gas into any suitable, usable byproduct.
  • the microorganisms may comprise algae adapted for fermentation of substrate carbon dioxide, whereby the system is adapted for the production of biodiesel.
  • the reactor assembly disclosed herein is used to produce hydrogen.
  • the process comprises (1) introducing into the reactor at least one species of microorganism, a liquid nutrient medium, and carbon monoxide to form a mixed liquor solids suspension (MLSS), wherein the microorganism is capable of converting carbon monoxide to hydrogen via water gas shift reaction; (2) photoactivating the microorganism; (3) circulating the MLSS in the circulation loop under anaerobic conditions; (4) injecting an inert gas into the fast-flow zone sufficient to create a gas lift pump; and (5) recovering hydrogen from the reactor.
  • MMLSS mixed liquor solids suspension
  • the species of microorganism comprises thermophilic Carboxydothermus hydrogenoformans Z-2901, Rubrivivax gelatinosus, Rhodospirillum rubrum., Bdellovibrio sp., Rhodopseudomonas palustris, Rhodobacter sphaeroides, Citrobacter sp. Y19, Methanosarcina acetivorans c2A, and Bacillus smithii.
  • the reactor assembly disclosed herein is used to produce hydrogen.
  • the process comprises (1) introducing into the reactor at least one species of microorganism, a liquid nutrient medium, and biomass to form a mixed liquor solids suspension (MLSS), wherein the microorganism is capable of converting biomass to hydrogen; (2) optionally photoactivating the microorganism; (3) circulating the MLSS in the circulation loop under anaerobic conditions; (4) injecting an inert gas into the fast-flow zone sufficient to create a gas lift pump; and (5) recovering hydrogen from the reactor.
  • the biomass comprises starch, sugar, or cellulose.
  • the reactor assembly disclosed herein is used to produce methane.
  • the process comprises (1) introducing into the reactor at least one species of microorganism, a liquid nutrient medium, and biodegradable biomass, to form a mixed liquor solids suspension (MLSS), wherein the microorganism is capable of fermenting the biomass to form methane; (2) optionally photoactivating the microorganism; (3) circulating the MLSS in the circulation loop under anaerobic conditions; (4) injecting an inert gas into the fast-flow zone sufficient to create a gas lift pump; and (5) recovering methane from the reactor.
  • the biodegradable biomass is selected from the group consisting of manure, wastewater sludge, and municipal waste.
  • the reactor assembly disclosed herein is used for an ABE fermentation process to produce a product selected from the group consisting of acetone, butanol, ethanol, and combinations thereof.
  • the process comprises (1) introducing into the reactor at least one strain of bacteria, a liquid nutrient medium, a carbon-rich substrate, to form a mixed liquor solids suspension (MLSS), wherein introduced bacteria are capable of fermenting the carbon-rich substrate to produce the product; (2) optionally photoactivating the microorganism; (3) circulating the MLSS in the circulation loop under anaerobic conditions; (4) injecting an inert gas into the fast-flow zone sufficient to create a gas lift pump; and (5) recovering the product from the reactor.
  • MLS mixed liquor solids suspension
  • the carbon-rich substrate comprises starch and sugar.
  • the inert gas includes nitrogen.
  • the reactor assembly disclosed herein is used for an energy production process to produce a biofuel.
  • the process comprises (1) introducing into the reactor at least one species of microorganism and a liquid nutrient medium to form a mixed liquor solids suspension (MLSS); (2) irradiating MLSS with light; (3) circulating the MLSS in the circulation loop; (4) injecting carbon dioxide into the fast-flow zone sufficient to create a gas lift pump; and (5) recovering from the reactor the biofuel.
  • the biofuel comprises biodiesel, bioethanol, or biobutanol.
  • the microorganism comprises algae.
  • the microorganism comprises bacteria.
  • FIG. 1 is a schematic illustration of a vertical shaft reactor assembly according to an embodiment of the invention.
  • FIG. 2A is a schematic illustration of a vertical shaft reactor assembly according to another embodiment of the invention.
  • FIG. 2A is a schematic illustration of a vertical shaft reactor assembly according to still another embodiment of the invention.
  • FIG. 3 A is a schematic illustration of a reactor assembly according to a further embodiment of the invention.
  • FIG. 3B is a schematic illustration of a reactor assembly according to still a further embodiment of the invention.
  • Figs. 4A and 4B are horizontal cross sections of respective embodiments of a vertical shaft reactor as shown in the system of Fig. 2A, 2B, 3 A, or 3B.
  • Fig. 4A shows an embodiment with one slow-flow zone and one fast-flow zone.
  • Fig. 4B shows an embodiment with one slow-flow zone and two fast-flow zones.
  • FIG. 5 illustrates an embodiment of a shaft reactor for fermenting CO to produce H 2 ;
  • Fig. 6A illustrates an embodiment of an enrichment system fluidly coupled to shaft reactor in vertical cross-section
  • Fig. 6B illustrates an embodiment of an enrichment system fluidly coupled to shaft reactor in horizontal cross-section
  • Fig. 7 illustrates an embodiment of shaft reactor head
  • Fig. 8 illustrates an embodiment of a cooling system and reactor access system
  • Fig. 9 illustrates an embodiment of cooling access system in horizontal cross-section.
  • Fig. 10 is another schematic illustration of a deep shaft reactor assembly.
  • Fig. 11 is a schematic of a deep shaft reactor system 20 according to an embodiment of this invention.
  • Fig. 12 is a schematic of a deep shaft reactor system 2OA according to another embodiment of this invention.
  • reactant is used in a generalized sense to include not only substances/reactants that are involved in the reaction but also inert substances that facilitate the reaction process (e.g., nitrogen gas).
  • mixed liquor suspended solids hereinafter used as “MLSS” is used in a generalized sense to refer to the solid- liquid mixture that is generated in a bioreactor.
  • the species of microorganism comprises any suitable species of microorganism currently known or that which is to be discovered or genetically modified/created in the future for each specific application.
  • Coupled to and “coupled with” includes fluid communication between the coupled components, either directly or indirectly, unless otherwise specified.
  • the concept of fluid communication includes the passage or flow of gas, gas mixture, liquid, liquid mixture, gas-liquid mixture, gas-solid mixture, liquid-solid mixture, and gas -liquid- solid mixture.
  • Indirect fluid communication means that there may be one or more intervening components between the coupled components.
  • Vertical shaft reactors disclosed herein include all such reactors for all purposes and applications, not limited by their size, shape, function, method of use, or material of make. In-ground, above-ground, or partially in-ground vertical shaft reactors are also included in this disclosure. Embodiments and related figures used herein are only exemplary and are not to limit the scope of the invention as set forth in the appended claims. Even though “deep shaft reactor” carries the denotation of an in-ground vertical shaft reactor, “vertical shaft reactor” and “deep shaft reactor” are interchangeably used in this disclosure, sometimes referred to as “shaft reactor”. DETAILED DESCRIPTION
  • an embodiment of a vertical shaft reactor assembly 10 comprises an enclosed head 40, a slow-flow zone 50 and a fast-flow zone 70.
  • the slow-flow zone 50 and fast-flow zone 70 are in fluid communication with each other directly and through the head 40.
  • the circulating liquid is sometimes referred to herein as the reaction medium or incubation mixture.
  • the reactor, and all parts exposed to the reaction medium are desirably made of stainless steel or are clad with stainless steel, or other suitable material for withstanding gases (e.g., CO 2 , H 2 ), water, and microbial mixture in the pH range from 7.5 to 9.5.
  • Head 40 is configured for receiving a liquid medium and any other substances necessary for carrying out the process.
  • Head 40 is also configured for removal of one or more reaction products.
  • Assembly 10 further includes a reactant enrichment chamber (REC) 80 in fluid communication with the sludge removal system connected to head 40 and fast-flow zone 70.
  • REC 80 is configured for receiving a reactant feed, and is in fluid communication with injection assembly 60.
  • Injection assembly 60 is in fluid communication with fast-flow zone 70.
  • a vertical shaft reactor system 200 includes reactor 230, one or more inlet lines 241 for feeding nutrients, water and microorganisms, reactant enrichment chamber 280, MLSS recycle unit (or biomass separation unit) 290, carbon source feed unit 300 and gas product recovery unit 310.
  • Reactor 230 includes head 240, slow-flow zone 250, injection assembly 260 having one or more nozzles 262 and fast-flow zone 270.
  • Injection assembly 260 is coupled to CO-saturation chamber 280.
  • Head 240 is coupled to fast-flow zone 270, gas recovery unit 310, and MLSS recycle unit 290.
  • Reactor 230 is a vertical shaft reactor with a head 240 and attached shaft 232.
  • Head 240 includes a lower basin 242, an upper headspace 244, and illumination assembly 246.
  • the illumination assembly 246 may be concealed into the roof (i.e., head 240) of the reactor to avoid chemical and humidity damage during operation, and to ensure that the appropriate light wavelength enters the basin portion 242.
  • the head 240 is made to be detachable from shaft 232.
  • head 240 has a larger diameter than the diameter of shaft 232, and therefore includes an annular extension 248', as illustrated in Fig. 2B, for example. In some embodiments, head 240 has a smaller diameter than that of shaft 232.
  • Head 240 includes one or more inlets 241 for introducing nutrients, microorganisms, sterile fresh water injection, pH adjusting agents, and other materials into the reactor.
  • Gas recovery unit 310 is coupled to headspace 244 via line 312.
  • MLSS recycle unit 290 is coupled to basin 242 of head 240 via line 296, and includes filtrate outlet line 292 and sludge outlet line 294.
  • water (filtrate outlet line 292) from the recycle unit 290 is suitable to be reused as water feed for the bioreactor. In such cases, filtrate outlet line 292 is coupled to the reactant enrichment chamber 280 so that regenerated water is mixed with a reactant in chamber 280.
  • MLSS recycle unit 290 may contain one or more centrifuge and ultrafiltration membrane, for example.
  • the shaft diameter is up to 6 meters (20 ft), and the depth of the shaft is up to 600 meters (2000 ft) deep.
  • the depth of the shaft to be used for a particular application is optimized based on the pressure sensitivity of the microorganism(s) to be used in the reactor, and other factors such as CO or CO 2 toxicity at various pressures. For instance, the depth of the shaft is about 150 meters (492 ft) in some cases.
  • the reactor has a large diameter deep shaft with a partition or separation wall 234 dividing the shaft 232 vertically into a slow-flow zone 250 and a narrower fast-flow zone 270.
  • the slow- and fast-flow zones are in indirect fluid communication at their upper ends 254 and 274, respectively, through the lower portion of head 240, also referred to as basin 242.
  • the slow- and fast-flow zones are in direct fluid communication at their lower ends 252 and 272, respectively.
  • Reactant enrichment chamber (e.g., gas saturation chamber) 280 may be located either above ground or below ground, and is coupled to water outlet line 292.
  • Line 292 is coupled to gas saturation chamber via line 282.
  • Line 282 includes a pump and venturi, in some embodiments. Known pumps and venturi devices may be employed for this purpose.
  • Carbon source feed unit 300 is coupled to chamber 280 via line 302 and line 282, as shown in Fig. 2A. The use of a Reactant enrichment chamber is especially advantageous when the carbon source is in gaseous form.
  • Saturating a liquid with the gaseous carbon source and providing the bioreactor with a gas-saturated liquid not only increases mass transfer to maximize production efficiency, but also reduces the energy necessary to inject gaseous feeds into the vertical shaft reactor. Furthermore, if inert gases are needed in the reaction process, a gas saturation chamber should also be used so that these gases are introduced into reactor zones at high pressures in their dispersed form in a liquid, which reduces the energy of gas injection.
  • Injection assembly 260 is coupled to saturation chamber 280 via line 284 and includes at least one injection nozzle 262, the first of which is located at the lower end 272 of zone 270.
  • assembly 260 includes a pump.
  • System 200 may also include a temperature control unit in thermal communication with reactor 230 and chamber 280. Dashed arrows indicate the primary direction of fluid circulation during operation of reactor 230.
  • system 200' includes an injection assembly 260' that includes a plurality of conduits and sprayers or nozzles 262' distributed along the length of fast-flow zone 270'.
  • assembly 260' also includes one or more pumps in electrical communication with a controller for regulating the injection characteristics of each sprayer. For example, in some applications the volume of gas/liquid dispersion per unit of time from different nozzles 262' varies along the length of zone 270'.
  • head 240' has a larger diameter than the diameter of shaft 232', and therefore includes an annular extension 248', which may serve as an overflow for basin 242'.
  • the illumination assembly (246 in Fig. 2A and 246' in Fig. 2B) is most useful in photofermentation processes, wherein reactions only proceed in the presence of light. In other processes, it is not necessary to provide light illumination during the course of the entire reaction. In such cases, the illumination assembly may be replaced by an external vessel with a radiation source, wherein the microorganisms are activated and then transferred into the vertical shaft reactor, as illustrated in Fig. 3A and 3B (external illumination assembly not shown).
  • the head 40', slow-flow zone 50', fast-flow zone 70', REC 80', and injection assembly 60' are analogous to the components shown in Fig. 1 , and are physically located substantially as shown. It should be noted that the drawings are schematic, and not necessarily drawn to scale.
  • the reactor assembly 10' is a vertical shaft reactor 30' with a head 40' and shaft 32'. Head 40' includes a lower region or basin 42' and headspace 44'. In some embodiments, head 40' is made to be detachable from reactor 30'. In some embodiments, head 40' has a larger diameter than the diameter of shaft 32', and therefore includes an annular extension 48', as illustrated in Fig. 3B.
  • Head 40' includes one or more inlets 41' for introducing into the reactor one or more reactants, microorganisms, nutrients, sterile fresh water injection, sterile recycled reactant medium filtrate, pH adjusting agents, or any other substances necessary to the selected process.
  • the reactor system also includes a sludge biomass separation unit (or a water recycle unit) 90' coupled to basin 42'.
  • recycle unit 90' includes filtrate outlet line 92' and sludge outlet line 94'.
  • recycle unit 90' may include a centrifuge unit and a filtration unit, for example.
  • the diameter of shaft 32' is up to 6 meters (20 ft), and the depth of the shaft is up to 600 meters (2000 ft) deep. For instance, the depth of the shaft is about 150 meters (492 ft) in some cases.
  • the depth of the shaft to be used for a particular application is optimized based on the pressure sensitivity of any microorganism(s) to be used in the reactor, and other factors such as reactant or product toxicity at various pressures.
  • reactor 30' has a shaft 32' with a partition or separation wall 34' dividing the shaft vertically into a slow-flow zone 50' and a fast-flow zone 70'.
  • the wall 34' is positioned such that zone 70' is narrower than zone 50'.
  • the slow- and fast-flow zones are in indirect fluid communication at their upper ends 54' and 74', respectively, through basin 42'.
  • Dashed line 43' indicates a fluid fill level during operation of the reactor.
  • the upper region of head 40', above line 43', is denoted headspace 44'.
  • the slow- and fast-flow zones 50', 70' are in direct fluid communication at their lower ends 52' and 72', respectively.
  • Dashed arrows indicate the approximate direction of fluid circulation during operation of the reactor.
  • the head zone 40' is coupled to the sludge removal system 90' and its water return line 41', which in some embodiments, includes a pump and venturi. Suitable pump and venturi systems are well known in the art, and may be similar to those used for dissolved air flotation systems, for instance.
  • Carbon source feed unit 100' is coupled to REC 80' via line 102' and line 82', as shown in Fig. 3A. Line 82' is positioned to withdraw liquid at lower end 52' of the slow-flow zone 50'.
  • REC reactant enrichment chamber
  • Saturating a liquid with the gaseous carbon source and providing the bioreactor with a gas-saturated liquid not only increases mass transfer to maximize production efficiency, but also reduces the energy necessary to inject gaseous feeds into the vertical shaft reactor. Furthermore, if inert gases are needed in the reaction process, a gas saturation chamber should also be used so that these gases are introduced into reactor zones at high pressures in their dispersed form in a liquid, which reduces the energy of gas injection.
  • the carbon source feed unit 100' is coupled directly to REC 80' so that the gaseous reactant and a portion of the liquid medium may be fed separately into REC 80'.
  • Injection assembly 60' is coupled to REC 80' and includes at least one injection port 62', the first of which is located at lower end 72' of zone 70' and in some cases at the lower end of 52'.
  • assembly 60' includes a pump.
  • System 10' may also include a temperature control unit in thermal communication with reactor 30' and REC 80'.
  • the reactant enrichment chamber 80' may additionally be used for nutrient mixing, pH control, and mixing of catalysts and liquids for various processes.
  • the injection assembly 60" includes a plurality of conduits and sprayers or nozzles 62" distributed along the length of fast-flow zone 70'.
  • assembly 60" also includes one or more pumps in electronic communication with a controller for regulating the injection characteristics of each sprayer 62".
  • FIG. 4A A schematic horizontal cross section view of an embodiment of a reactor 230, configured as described in Fig. 2A, 2B, 3A, or 3B, is shown in Fig. 4A.
  • Shaft 232 includes one slow-flow zone 250 and one fast-flow zone 270.
  • the slow- and fast-flow zones are divided by a partition or wall 234, which is positioned so that the volume of slow-flow zone 250 is greater than the volume of fast- flow zone 270, i.e., the horizontal cross section of zone 270 is smaller than that of zone 250.
  • FIG. 4A A schematic horizontal cross section view of an embodiment of a reactor 230, configured as described in Fig. 2A, 2B, 3A, or 3B, is shown in Fig. 4A.
  • Shaft 232 includes one slow-flow zone 250 and one fast-flow zone 270.
  • the slow- and fast-flow zones are divided by a partition or wall 234, which is positioned so that the volume of slow-flow zone 250 is greater than the volume of fast
  • the reactor of Fig. 2A/2B or 3A/3B is configured substantially as illustrated in Fig 4B.
  • a horizontal cross section of a reactor 330 is shown, which includes two fast-flow zones 370a, 370b located on opposite sides of the reactor shaft 332.
  • One slow-flow zone 350 is disposed between the two fast-flow zones 270a, 270b.
  • This configuration may include two nozzle assemblies like assembly 60" disposed along opposite walls of the reactor, and may be advantageous for handling especially large volumes of reactant gas. In many cases, one or more assembly 60" promotes enhanced gas to liquid transfer rates, and permits effective gas injection control.
  • the reactor assembly 10' also includes cooling control means, is able to run at high pressures, and includes cleaning means to avoid contamination (e.g., contamination with undesirable microorganisms and reactants).
  • contamination e.g., contamination with undesirable microorganisms and reactants.
  • An exemplary type of process that may be carried out using an above-described reactor assembly is the anaerobic microbial water shift reaction of carbon monoxide gas (CO) to generate molecular hydrogen (H 2 ).
  • CO carbon monoxide gas
  • H 2 molecular hydrogen
  • Carbon monoxide serves as the sole carbon source for the selected microorganisms.
  • an aqueous medium containing suitable H 2 -producing microorganisms is introduced into the slow-flow zone of an in-ground reactor such as that shown in Fig. 3B.
  • Examples of potentially suitable microorganisms for production of hydrogen from carbon monoxide feed are represented by a group of bacteria that consume carbon monoxide under aqueous anaerobic conditions and release H 2 , including thermophilic Carboxydothermus hydro genoformans Z-2901, Rubrivivax gelatinosus and Rhodospirillum rubrum.
  • Some additional examples of bacteria that are potentially suitable for production of hydrogen include Bdellovibrio sp., Rhodopseudomonas palustris, Rhodobacter sphaeroides, Citrobacter sp. Y19, Methanosarcina acetivorans c2A, and Bacillus smithii.
  • An incubation mixture containing a nutrient solution lacking a carbon source is introduced into reactor 30' via one or more inlet 41'.
  • the reactor is filled to a predetermined fill line or level 43' in head 40', as illustrated in Fig. 3B.
  • the lower region of head 40' between the fill line 43' and the top ends 54', 74' of zones 50' and 70' is referred to as basin 42'.
  • the microorganisms are activated (i.e., the CO-oxidation pathway including the water-gas shift reaction is induced) by exposing the microorganisms in basin 42' to light in the visible wavelength range.
  • a suitable illumination means such as incandescent lamps may be provided in head 40', or the requisite light exposure may be performed prior to injection of the microorganisms into the reactor.
  • the length of time of exposure to light is determined based on the parameters of a given application, such as flow rate of the incubation mixture, the intensity of the light, the exposed surface area of the incubation mixture in head 40'. As illustrated in Fig. 3B, in some embodiments of the process, the reactor head 40' has a diameter greater than that of shaft 32'.
  • Such a configuration enhances exposure of the circulating microorganisms to light prior to flowing downward into the darkened slow-flow zone 50' of reactor 30', in embodiments in which the light source is disposed in head 40'.
  • fermentation of CO with the next effect of a water-gas shift reaction, will continue in the presence of light, endogenous hydrogenases may potentially oxidize the product H 2 to support light-dependent CO 2 fixation. Therefore, after activation, it may in some applications be desirable to perform the subsequent stages of the fermentation process in the absence of light to enhance the yield of H 2 product.
  • the desired biochemical reaction benefits from the CO feed gas starvation stage of the process, as the food-deprived microorganisms are primed for enhanced metabolic activity upon restoration of a food source (i.e., carbon monoxide).
  • a food source i.e., carbon monoxide.
  • the same benefit would not be achieved by merely injecting a CO-containing feed gas into a conventional batch fermentation mixture.
  • the light-activated incubation mixture initially incubates in a relatively slow-flowing downward stream in the slow-flow zone 50' of the reactor 30' (the CO-depleted slow-flow stage).
  • the microorganisms remain or become depleted in the CO carbon source.
  • the CO-depleted incubation mixture is then mixed with a carbon monoxide saturated feed (from the CO- saturation stage) to form a CO-enriched or saturated incubation mixture.
  • carbon monoxide is the reactant that is enriched into the water phase.
  • the CO- starved mixture is transferred from slow-flow zone 50' into the fast moving zone 70'.
  • CO is saturated into the liquid withdrawn from the vertical shaft bioreactor in REC 80'. In some cases this is done using a high-pressure pump and a venturi device.
  • the high pressure pump and venturi device combine the incubation mixture in line 82' and a CO feed gas, thereby enriching, saturating, or even supersaturating the incubation mixture with carbon monoxide.
  • CO is saturated into the regenerated water from the sludge separation unit 290' in REC 280' as illustrated in Fig. 2B.
  • Mass transfer of CO into the liquid phase of the incubation mixture is enhanced by carrying out the process in a deep shaft reactor, by forming a fine dispersion of the gases in the liquid phase, and by application of pressure and maintenance of a temperature at which production of H 2 is promoted.
  • Any suitable means for regulating the temperature of the incubation mixture may be used, such as employing heating and cooling techniques that are known in the art.
  • the CO- saturated mixture is injected via an injection assembly 60" (e.g., an array of sprayer nozzles 62") into the fast-flow zone (CO rich fast-flow stage).
  • the circulation flow pattern is thus propagated by injection of CO on one side of the reactor (i.e., zone 70'), forcing the incubation mixture into motion between the fast-flow (70') and slow-flow (50') zones.
  • the injected CO dissolves in the incubation mixture as the CO-containing gas is dispersed in the liquid phase.
  • This dissolved carbon monoxide provides the necessary carbon source for the activated microorganisms to carry out the water-gas shift reaction.
  • the activated microorganisms in the CO-enriched incubation mixture form H 2 and CO 2 from the dissolved carbon monoxide.
  • the metabolic process by which H 2 is generated occurs in the fast moving zone 70', during transfer and subsequent injection into the fast-flow zone of the reactor, and during circulation through the fast-flow zone.
  • the production of H 2 may also occur as the incubation mixture circulates through the lower portion (basin) of the reactor head.
  • the incubation mixture is circulated repeatedly between the downflow chamber (“downcomer”), which comprises the CO-depleted slow-flow zone 50', and the upflow chamber (“riser”), which comprises the CO-rich fast-flow zone 70'.
  • the incubation mixture is driven through the fast-flow zone primarily by injection of CO-saturated incubation mixture into only the rapid flow zone 70' and at times in the lower part of the downcomer zone 52'.
  • the undissolved gas, including primarily CO, H 2 and CO 2 , in fast-flow zone 70' provides gas lift to drive circulation of the incubation mixture from fast-flow zone 70' into head 40'.
  • the incubation mixture in the downcomer i.e., zone 50'
  • reactor head 40' is constructed for vacuum degasification.
  • the application of vacuum promotes disengagement and removal of hydrogen gas from the incubation mixture as it circulates through basin 42' prior to reentry of the incubation mixture into slow-flow zone 50'. Rapid removal of the off-gases from the incubation mixture deters potential toxic effects of CO and other gases on the microorganisms, and reduces the propensity of undesirable side reaction.
  • the evolved gases are collected and extracted from the reactor via vacuum, and the H 2 product is recovered from the vacuum extracted gas.
  • Biomass Removal The microorganisms metabolize and proliferate, in some cases doubling in population after two hours of processing. To maintain a desired concentration of microorganisms, all or a portion of the circulating incubation mixture is removed from the reactor and treated to remove excess or spent microorganisms. Such treatment may comprise filtration, centrifugation, or a combination of those, for example. If suitable, regenerated water after biomass removal is reused as feed water for the bioreactor. If desired, the resulting sludge may be recycled as combustible biomass, for further production of carbon monoxide feed gas.
  • Any suitable carbon monoxide-containing gas may serve as the feed for enriching the incubation mixture with CO, provided that the concentration of other gaseous components of the feed are not prohibitively toxic to the selected microorganisms. Accordingly, for some applications it may be desirable to include a feed gas pre-cleaning step to remove any components that are potentially detrimental to the selected microorganisms.
  • suitable synthesis gas cleanup techniques are known in the art and have been described in the literature.
  • the flow of fresh sterile water, nutrients and fresh microorganisms into reactor head and the withdrawal of spent incubation mixture from reactor head are controlled.
  • the H 2 product exits headspace, and in some applications is removed by the gas recovery unit.
  • a portion of the recovered H 2 is combined with the CO feed stream to dilute CO concentration.
  • the pH of the water mixture may be controlled to convert dissolved CO 2 into bicarbonate to prevent CO 2 acidity from prohibiting the microbial water shift reaction to produce H 2 .
  • FIG. 5 shows an embodiment of reactor system 10 configured for fermentation, waste treatment, and mixed liquor suspended solids (MLSS) circulation via a water-gas shift reaction.
  • Reactor system 10 circulates a MLSS suspension through an apparatus that comprises vessel 12, mixing system 30, and reactant source 34.
  • Vessel 12 has reactor volume 20, head 50, and radiation system 14.
  • Vessel 12 is configured for fluid flow or circulation 18 about division 16.
  • Head 50 includes a vent system 52 for removing gases, such as hydrogen (H 2 ).
  • the water-gas shift reaction in the reactor system 10 is a carbon neutral operation. Without being limited by theory, greenhouse gases and compounds produced by the reaction are removed as chemical salts, liquids, solids, or another means. In further instances, reactor system 10 may be coupled to a facility for producing syngas from biomass and/or coal, thereby enhancing sequestration of carbon dioxide, and/or other greenhouse gases.
  • Vessel. Vessel 12 is a cylinder having a top 12a and bottom 12b. In certain embodiments, the vessel 12 has a long axis L a oriented vertically between the top 12a and the bottom 12b. Long axis L a is between about 10 m and about 600 m.
  • Short axis S a is selected, or built, to configure reactor system 10 for optimal MLSS circulation time.
  • Short axis S a is oriented horizontally between vessel walls 12c; alternatively perpendicular to long axis L a .
  • Short axis S a is selected, or built, to configure reactor system 10 for optimal MLSS circulation volume.
  • Short axis S a is the inner diameter of the vessel in cylindrical embodiments.
  • Vessel 12 may have alternative shapes such as without limitation, rectangular, or polygonal.
  • vessel 50 is a shaft reactor.
  • a shaft reactor is any reactor that has a long axis L a that is at least twice the dimension of the short axis S a .
  • vessel 50 is disposed below ground, for instance in a shaft, borehole, or other vertically oriented compartment in the earth.
  • vessel 12 is at least partially above ground.
  • vessel 12 is a deep shaft reactor, wherein long axis L a is greater than about 50m.
  • Vessel 12 is constructed of any material suitable for resisting corrosion. Further, vessel 12 is constructed of a thermally conductive material for transferring heat to surroundings, such as the ground. In certain embodiments, vessel 12 is constructed of aluminum, or stainless steel. Vessel 12 comprises any suitable vessel for carrying out a fermentation reaction. In embodiments, vessel 12 is a pressurized vessel, reactor, container or the like configured to contain a fermentation reaction, for example H 2 production via CO fermentation. Vessel 12 may have any shape or size suitable for containing a CO fermentation reaction. Alternatively, vessel 12 is configured to hold a reaction mixture comprising wastewater. Vessel 12 is configured to contain a carbon monoxide fermentation mixture including wastewater.
  • vessel 12 comprises any suitable for containing MLSS suspension of reactants, products, solids, liquids, and gases without limitation, for CO fermentative H 2 production. Further, vessel 12 and all internal structures are coated, treated, or polished to prevent the formation of bacterial biofilms or other microorganism plaques.
  • Vessel 12 has reactor volume 20. Reactor volume 20 extends from vessel bottom 12b to reactor volume surface 22. Reactor volume surface 22 comprises a fluid/gas interface within vessel 12. Reactor volume 20 is between about 50 % and about 99% of the total volume of vessel 12. Total volume of vessel may be calculated by ⁇ L a (S a /2) 2 . Reactor volume 20 is a fluid volume configured to include circulation 18, and division 16. Alternatively, reactor volume 20 is an internal compartment of vessel 12.
  • division 16 is a virtual division, wherein the reactor volume 20 is a unified volume.
  • division 16 is an axis of circulation in which the MLSS suspension circulates through reactor volume 20.
  • Division 16 may comprise an area of shear, such that fluid flowing downward and fluid flowing upward interact.
  • division 16 is a baffle, wall, or other component of vessel 12 to direct or control fluid flow.
  • Division 16 may be oriented in any direction with respect to long axis L a of the vessel 12. In preferred embodiments, division 16 is oriented vertically, or parallel to long axis L a .
  • Division 16 extends a partial distance through reactor volume 20 a parallel to long axis L a .
  • Division 16 extends parallel to short axis S a , in embodiments division 16 divides the reactor volume 20 into at least two compartments: a first compartment 20a, and a second compartment 20b. In certain embodiments, division 16 is vertical contact with vessel walls 12c. Compartments 20a, 20b created by division 16 are about equal in volume. Alternatively, as illustrated in Figures 6 A and 6B, division 16 creates a first compartment 20a with a volume that is greater than about the volume of the second compartment 20b. First compartment 20a has a volume of at least about 51% of reactor volume 20. Second compartment 20b has a volume of maximum about 49%. In certain instances, a configuration with unequal compartment volumes is a configuration for altering the velocity of circulation 18 between the first compartment 20a and the second compartment. 20b.
  • first compartment 20a is a downcomer compartment. Further, the downcomer, or first compartment 20a, is configured for slow suspension flow or circulation 18a. Direction of circulation 18a is generally directed towards the bottom 12b of vessel. First compartment 20a is a reactant depleted flow region within vessel 12. In embodiments, first compartment 20a comprises a CO-depleted flow in reactor.
  • compartment 20b is a riser compartment.
  • the riser or second compartment 20b is configured for fast suspension flow, or circulation 18b.
  • second compartment 20b is configured a gas lift compartment.
  • Direction of circulation 18b is generally directed towards reactor volume surface 22 and top 12a of vessel.
  • Second compartment 20b is a reactant enriched flow region within vessel 12.
  • second compartment 20b comprises a CO enriched flow in reactor.
  • second compartment 20b is configured for fast flow to reduce accumulation of toxic compounds to microorganisms for fermentation.
  • division 16 includes gaps, openings, or the like, without limitation.
  • Top gap or spillover 16a located proximal to the surface 22 of reactor volume 20.
  • Spillover 16a is configured to allow circulation 18 to continue over or around division 16 between compartments 20a, 20b.
  • division 16 includes lower gap or flow-through 16b, that is configured such that circulation 18 continues under, or around division 16 between compartments 20a, 20b.
  • spillover 16a and flow- through 16b are constructed to increase turbulence and mixing of MLSS.
  • division 16 includes baffles, fins, or other turbulence inducing structures. Furthermore, these structures may be disposed on vessel walls 12c.
  • Division 16 is constructed such that circulation 18 may continue in any direction such that MLSS suspension in vessel 12 are circulated from top to bottom to top of reaction volume 20 about division 16 and between first compartment 20a, and second compartment 20b.
  • FIG. 6A a vertical cross-section of vessel 12 for reactor system 10.
  • Vessel is coupled to mixing system 30 via outlet system 32, and injector system 36.
  • Outlet system 32 withdraws MLSS suspension from vessel 12, that via a centrifuge separates biomass and return the water to mixing system 30.
  • Mixing system comprises mixing vessel 38 coupled to reactant source 34 by reactant stream 40.
  • Injector system 36 reintroduces the enriched CO-Water gas suspension from mixing system 30 to vessel 12 for further processing.
  • Mixing system 30 saturates reactants in the water return using reactant from source 34.
  • Mixing system 30 is configured to enhance, or enrich and super saturate water suspension with reactants in mixing vessel 38 for re-introduction to vessel 12.
  • mixing system 30 is configured for saturating the return water suspension with CO gas.
  • Mixing vessel 38 may comprise a reactor, a vessel, a tank, or the like for holding a gas water mixture reaction for saturation.
  • Mixing vessel comprises inlet 38a and outlet 38b.
  • inlet 38a and outlet 38b are valves to alter, restrict, or stop the flow of a liquid or gas therethrough.
  • mixing vessel 38 is a holding tank or storage vessel, for maintaining the suspension in contact with reactant stream 40.
  • mixing vessel 38 enriches the suspension by agitating, or stirring the suspension.
  • Mixing vessel 38 may be configured to maintain a flow path or enriching circulation 118.
  • Mixing vessel 38 may include internal structures designed to direct, or improve enriching circulation 118, such as, but not limited to conduits, baffles, sluices, settlers, and filters.
  • Reactant source 34 comprises a source of raw material or compounds for participation, acceleration, catalysis of, or interaction with the MLSS suspension, without limitation.
  • reactant source 34 comprises a CO gas source.
  • reactant source 34 comprises any gaseous reactant suitable for a fermentation reaction, fermentation reaction to produce H 2 , or other reaction to produce gaseous fuel products.
  • Reactant source 34 is fluidly coupled to mixing vessel 38 by reactant stream 40.
  • reactant stream 40 feeds directly into mixing vessel 38 and enriching circulation 118 contained therein.
  • Reactant stream 40 comprise a control means to adjust the CO gas feed into mixing vessel 38. In certain instances, reactant stream 40 is adjusted to modulate at least one gaseous component's concentration in mixing vessel 38.
  • Exemplary adjustments reactant stream 40 is configured to include, without limitation, reactant flowrate, reactant pressure, and/or reactant concentrations. In embodiments, reactant stream 40 is configured to adjust and monitor CO-containing gases.
  • Outlet system 32 is fluidly coupled to mixing vessel 38. Outlet system 32 comprises any conduit suitable for withdrawing the MLSS suspension from vessel 12, to mixing vessel 38, via a centrifuge to separate biomass, without limitation. In certain instances, a plurality of suitable conduits may be used to maximize the volume of MLSS suspension withdrawn from vessel 12 to meet the water volume requirements to feed CO gas and to separate biomass. In embodiments, outlet system 32 withdraws MLSS suspension adjacent to head 20b of vessel 12.
  • outlet system 32 is configured to withdraw MLSS suspension adjacent to flow- through 16a (figl).
  • the outlet system 32 is disposed in first compartment 20b, adjacent to flow-through 20a-20b, and adjacent to head 16a (figl).
  • outlet system 32 is disposed in second compartment 20b, adjacent to flow-through 16b, and adjacent to vessel bottom 12b.
  • Outlet system 32 withdraws MLSS suspension from 20b to mixing vessel 38.
  • outlet system 32 includes a venturi pump 144.
  • Venturi pump 144 is configured to pump suspension from vessel 12 into mixing vessel 38 prior to centrifuge separation of MLSS.
  • venturi pump 144 is configured to pump, or inject, reactant feedstream 40 from reactant source 34 into MLSS suspension in reactor 12.
  • the use of a venturi pump 144 may act to eliminate the need for compressing the reactant gases to ensure sufficient pressure during injection at certain depths of the reactor 12.
  • venturi pump 144 comprises a venturi driven liquid/gas injection system. Venturi pump 144 is further configured for pumping pressurized or non-CO gas into MLSS suspension via a vacuum generated in the venturi.
  • venturi pump 144 lyses, kills, ruptures, or otherwise reduces the microorganism population in MLSS suspension prior to introduction into mixing vessel 38. In certain instances, this is beneficial to the overall operation of the reactor system 10 as the ruptured cells increase the abundance of certain biomaterials as the MLSS suspension is enriched in mixing vessel 38.
  • injector system 36 introduces saturated CO-Gas water mixture suspension from mixing system 30 to second compartment 20b.
  • injector system 36 is constructed to have a plurality of injectors 137.
  • injectors 137 comprise any suitable device for injecting a suspension, emulsion, solution, foam, or gas- liquid mixture stream without limitation.
  • injector system 36 comprising injectors 137, injects CO enriched, or enhanced, water-gas suspension from mixing system into second compartment 20b.
  • Injectors 137 are disposed on vessel wall 12c; alternatively mounted in vessel wall 12c.
  • injectors 137 may comprise nozzles, configured for spraying a plurality of enriched streams 139 into vessel 12.
  • Enriched streams 139 are gasified, CO gas enriched, or CO gas enhanced super saturated CO-water gas suspension streams. Further, enriched streams 139 provide gas-lift to compartment 20b.
  • injector system 36 in is fluid communication with a cleaning stream 170.
  • Injector system 36 includes at least one injector 137 in fluid communication with mixing vessel 38 and cleaning stream 170.
  • injectors 137 are configured for clean-in-place (CIP) processes.
  • additional injectors 137a having cleaning streams 139a are disposed in the first compartment 20a for CIP processes.
  • injectors 137 are Alfa-Laval (Toftejorg) Nozzles or other 360 degree water pressure activated vertical-horizontal rotary type of spray nozzles specifically designed for this application or preferably standard units available commercially.
  • Outlet valve 38b prevents cleaning stream 170 contamination of mixing vessel 38.
  • injector system 36 is controlled by outlet valve 38b.
  • Outlet valve 38b is configured to seal mixing vessel from injector system 36.
  • pressurization of injector system 36 with a cleaning solution from cleaning stream 170 activates outlet valve 38b to close.
  • cleaning stream 170 comprises separate injectors disposed within vessel 12.
  • outlet valve 38b is open.
  • cleaning stream 170 is fluidly connected coupled to venturi pump 144 in order to clean all mixing system 30 components.
  • cleaning stream 170 may include toxic, caustic, and/or potential contaminants to the MLSS suspension.
  • cleaning stream 170 comprises caustic soda, chlorine, acid, biocides, high-pressure steam, or combinations thereof without limitation.
  • cleaning stream 170 may comprise certain anti-biotic, antimicrobial, anti-fungal, or anti-viral compounds without limitation.
  • Vessel Head Referring now to Figures 5 and 7, head 50 comprises recycle system 90, vent system 52, and radiation system 14. Further, head 50 includes headspace 250 for capturing gases. Headspace 250 is configured to capture gases released from the fermentation reaction in reactor volume 20 MLSS suspension. Headspace comprises between about 1% and about 50% of total reactor volume.
  • headspace 250 is applied with a vacuum to capture and harvest the H 2 gas from a CO fermentation reaction.
  • Head 50 is disposed proximally to the vessel top 12a, and above reactor volume 20. Head 50 has a diameter H a , that is at least the same length as short axis S a . In embodiments, head diameter H a , is larger than short axis S a . Head 50 is disposed at least level with or above ground level 1. In certain instances, head 50 may be partially below ground level 1.
  • Recycle system 90 comprises sludge outlet 92, filtrate return 94, and floculant feed 96.
  • sludge outlet 92 is a conduit that removes suspension from reactor volume 20 to recycle system 90 for filtration using a centrifuge. Sludge outlet 92 is in fluid communication with MLSS suspension proximal to vessel top 12a, reactor volume surface 22, division spillover 16a, and/or combinations thereof.
  • Recycle system 90 is configured to remove waste products, suspended solids, and the like from the MLSS suspension and return the water for CO gas saturation in 38.
  • recycle system 90 may comprise a membrane filter, centrifuge, chemical precipitation, settling, or other treatment processes to remove solids from a suspension, as known to one skilled in the art.
  • Recycle system 90 returns filtrate to the vessel 12 via filtrate return 94.
  • filtrate return 94 is in fluid communication with reactant chamber 38. Filtrate return 94 is fluidly coupled to reactor volume 20 proximal to second compartment 20b via injector system 137.
  • the filtrate return 94 feeds mixing vessel 38 for CO-Saturation of the return water.
  • the separation via venturi pump 144 may cause physical stress or death to the microorganisms.
  • outlet system 32 is repositioned to work in conjunction with sludge outlet 92 (not shown) and recycle system 90.
  • Recycle system 90 comprises flocculant dosing stream 96.
  • Nutrient feed stream 96" feeds directly into head 50.
  • flocculant stream 96 comprises a make-up water feed stream.
  • Stream 96 is configured to provide make-up water topping up water to maintain tank level 22.
  • Feed stream 96 V restores certain nutrients, and liquids, to vessel volume 20 directly to the head 250.
  • nutrient feedstream 96' is configured to deliver an aqueous suspension of nutrients to vessel 12.
  • Nutrient feedstream 96' may comprise any nutrients, or media, beneficial to microorganisms used for a hydrogen fermentation process.
  • Nutrient feedstream 96' is additionally configurable for delivery of chelating compounds, quenching compounds, isolating compounds, or other compounds known to one skilled in the art for removing or mitigating the increase of toxic compounds in the MLSS.
  • nutrient feedstream 96' adds hydroxide salts to the MLSS to control build up of carbon dioxide (CO 2 ) by converting them into bicarbonate, which is toxic to microorganisms responsible for the CO fermentation.
  • the pH of the MLSS is maintained up to about pH 10.
  • nutrient feedstream 96' may comprise a feed of additional microorganisms suitable for CO fermentation to produce H 2 gas.
  • suitable microorganisms are represented by a group of bacteria that consume carbon monoxide under aqueous anaerobic conditions and release H 2 in a water shift reaction, including thermophilic Carboxydothermus hydrogenoformans Z-2901, Rubrivivax gelatinosus, and Rhodospirillum rubrum.
  • Alternative potentially suitable organisms may include Bdellovibrio sp., Rhodopseudomonas palustris, Rhodobacter sphaeroides, Citrobacter sp.
  • nutrient feedstream 96 it is preferable for nutrient feedstream 96 to include CO fermenting microorganisms that are resistant to certain toxins and pollutants, such as but not limited to sulfides, nitrates, nitrides, and oxides.
  • Vent system 52 comprises a means to remove gases from headspace 250.
  • vent system 52 is configured to remove H 2 gases from vessel 12 and head 50 via headspace 250.
  • vent system 52 comprises any means known to one skilled in the art for removing, and/or isolating hydrogen from product gases to produce H 2 gas stream 252.
  • vent system 52 comprises a system for applying a vacuum to headspace 250. Examples of suitable systems include, but are not limited to blowers and mechanical vacuum systems, chemical vacuum systems, or combinations thereof as known to one skilled in the art. Chemical vacuum systems may include preferential absorption of a gas component, for example hydrogen, by a membrane.
  • vent system 252 comprises gas recycle stream 254. In certain instances, gas recycle stream 254 is in communication with reactant source 34.
  • Head 50 comprises radiation source 14, disposed at or above the vessel top 12a. Radiation source 14 is disposed above or in headspace 250. In certain instances, radiation source 14 is hermetically sealed from headspace 250 to improve durability. Keeping radiation source 14 hermetically sealed from headspace 250 reduces exposure to corrosive gases, high humidity, and fluctuating temperatures. In embodiments, radiation source 14 is configured to provide radiation to reactor volume surface 22 through out head 50. Radiation source 14 may be configured to provide radiation to a portion of reactor volume surface 22. Radiation source 14 may further comprise a plurality of radiation components 214. Radiation components 214 may be bulbs, tubes, electrodes, light emitting diodes, or other electromagnetic emission sources. In certain instances, radiation components 214 are bulbs.
  • Radiation source 14 may further comprise optic channels, or optical paths to transmit light into reactor volume 20.
  • Radiation source 14 is configured to provide radiation for activation of microorganisms. Specifically, radiation source 14 may be targeted to specific wavelengths of light understood by one skilled in the art to activate a CO oxidation pathway. Alternatively, radiation source 14 may be configured to provide radiation for sterilization of reactor volume 20. In sterilization embodiments, radiation source 14 may comprise ultra-violet (UV) lights configured to eliminate microorganisms. Additionally, radiation source 14 may comprise infrared (IR) emitters, or heaters, in order to raise the temperature of headspace 250, reactor volume surface 22, or reactor volume 20.
  • IR infrared
  • Head 50 is a de-gassed photochamber.
  • the de-gassed photochamber has a vacuum applied to remove gas released into the headspace 250 for capturing and isolating gas for additional purposes.
  • head 50 captures hydrogen gas from CO fermentation for fuels, fuel cells, and other purposes as known to one skilled in the art.
  • Application of a vacuum to headspace 250 via vent system 52 is configured to control gas production in vessel 12. In certain instances, the partial pressure of hydrogen in headspace 250 dictates the production rates of hydrogen throughout the reactor system 10.
  • headspace 250 may be controlled to maintain a high hydrogen partial pressure in order to control toxic compounds in MLSS throughout reactor volume 20, as a high H 2 partial pressure may slow further fermentation reactions.
  • vacuum acts to remove certain gas particles, for example oxygen radicals, which may deflect, absorb, impede, or otherwise inhibit emitted radiation from radiation source 14 from impinging on reactor volume surface 22.
  • head 50 may be configured to control overall CO fermentation to H2 rate by radiation source 14.
  • Radiation source 14 activated, flashed, or otherwise operated intermittently, serving to activate only a portion of the microorganisms, for example those located at or near reactor volume surface 22, at a given time. Alternatively, the radiation source 14 is activated at time, cycle, or gas product concentration determined periods.
  • reactor system 10 comprises cooling system 80.
  • Cooling system 80 comprises at least one cooling vessel 82 disposed circumferentially and spaced a distance D v from the walls 12c of vessel 12. Cooling vessel 82 extends below vessel bottom 12b. Cooling vessel 82 may be concentric to vessel 12. Cooling vessel 82 comprises internal space 84. Cooling vessel 82 is configured to maintain a specific temperature range within reactor volume 20. Cooling vessel 82 is configured to maintain a temperature range of between about 20-38 0 C and about 38-60 0 C.
  • Cooling vessel 82 may be a solid vessel, wherein internal space 84 comprises a material with efficient thermal transfer properties, for instance a heat sink. Cooling vessel 82 may comprise a layer of metallic material disposed on the outer surface of vessel 12, for example, aluminum. In certain instances, internal space 84 is filled with an insulating layer, or insulation, such as foam, fiberglass, comprising materials such silicon oxide, polyurethane, polypropylene, or other materials as known to one skilled in the art. Cooling vessel 82 may be configured to insulate vessel 12 from the earth.
  • internal space 84 is a fluid conduit configured for the circulation of cooling fluids about vessel 12.
  • internal space 84 comprises inlet 84a and outlet 84b.
  • suitable cooling fluids are water, polyethylene glycol, glycerol, or others known to one skilled in the art, without limitation.
  • In internal space 84 may comprise a continuous volume, or bath of cooling fluid. Cooling fluid may be batch processed in cooling vessel 82. For example, cooling fluid remains in internal space 84 during running of reactor system 10 for a pre-determined period. After which, fresh fluid is introduced via inlet 84a. Alternatively, heated fluid may be withdrawn from outlet 84b by a pump, vacuum, filter, or the like, without limitation.
  • internal space 84 may comprise a continuous, annual conduit, such as a coil (not shown) for circulation of fluid about vessel 12.
  • internal space may comprise a plurality of vertically oriented conduits disposed about the vessel wall 12c.
  • internal space 84 comprises a baffle 88 as illustrated in Figure 9.
  • Baffle 88 comprises a wall, disposed radially within internal space 84 of cooling vessel 82, between vessel wall 12c and cooling vessel wall 82c.
  • baffle 88 is a vertical contact with vessel walls 12c and cooling vessel wall 82c.
  • baffle 88 runs extends vertically from reactor volume surface 22 to reactor bottom 12b.
  • Baffle 88 divides internal space 84 of cooling vessel into two compartments, a first compartment 82a disposed proximal to inlet 84a, and a second compartment 82b, disposed proximal to outlet 84b. Compartments 82a, 82b created by baffle 88 are about equal in volume.
  • baffle 88 creates a first compartment 82a with a volume that is greater than about the volume of the second compartment 82b.
  • First compartment 82a has a volume of at least about 51% of cooling vessel 82 internal volume.
  • Second compartment 82b has a volume of maximum about 49% of cooling vessel 82 internal volume.
  • the compartment 82a, 82b volumes are reversed, wherein first compartment 82a volume is less than about second compartment 82b volume.
  • a configuration with unequal compartment volumes is a configuration for altering the velocity of cooling fluid circulation between the first compartment 82a, and the second compartment 82b.
  • inlet 84a is disposed proximal to second compartment 20b of vessel 12. Further, first compartment 82a is disposed annularly about second compartment 20b of vessel 12. Cooling system 80 is configured such that cooling fluid 89 flows into cooling vessel 82 via inlet 84a, into first compartment 82a and vertically towards vessel bottom 12b. Further, baffle 88 directs cooling fluid below vessel bottom 12b, where cooling fluid 89 travels vertically upwards to outlet 84b in second compartment 84b.
  • reactor system 10 comprises access system 70.
  • Access system 70 comprises a shaft 71, and a personal transport car 72.
  • the transport car 72 having a first position 72a, disposed at, or above, ground level 1 , for allowing personnel, equipment, and material to access the interior of the transport car 72.
  • Transport car 72 is configured to travel the length of vertical, or long, axis L a . It can be envisioned that transport car comprises a bottom, or second position 72b at about the bottom 12b of vessel 12.
  • transport car 72 is configured for coupling to access means 74 in order to gain internal access to cooling vessel 82 and vessel 12 to allow for maintenance, repair, replacement, inspection, cleaning, or other operations within reactor system 10, and vessel 12, below ground level 1.
  • transport car 72 may be configured as access means 74, wherein the shaft 71 is disposed within the vessel walls 12c.
  • shaft 71 may comprise an internal component of vessel 12.
  • transport car 72 may have a plurality of discrete positions, or access points (not shown) in which to provide internal access to reactor system 10. Oxidative Wastewater Treatment
  • a stream of influent wastewater is fed into reactor 30 through head 40, via one or more inlets 41.
  • Shaft 32 and head 40 are filled to a desired operating fill level or line 43 in head 40.
  • Aerobic microorganisms capable of oxidizing the organic substances in the wastewater are added.
  • a portion of the effluent recycle fluid from biomass extraction unit 90 may be fed into retention chamber 80 via return water filtrate line 98, in combination with a stream of oxygen- containing gas via fermentation feed gas inlet line 21.
  • the oxygen-containing gas is sometimes referred to herein as "oxygen" or "air.”
  • a high pressure pump and venturi device may be utilized to combine the effluent recycle fluid and air upstream retention chamber 80, thereby intimately mixing the fluid with CO.
  • the gas/liquid mixture from retention chamber 80 is saturated or supersaturated with oxygen.
  • the oxygen-saturated fluid also containing undissolved air bubbles, is injected into zone 70 via nozzle assembly 60, creating a gas-lift pump in zone 70.
  • dissolution of oxygen into the fluid is enhanced compared to conventional diffused aeration techniques. This dissolved oxygen constitutes the principal reactant in the biochemical degradation of suspended or dissolved organic matter in the wastewater.
  • the wastewater in zone 50 has a higher density than the liquid-gas mixture in zone 70.
  • the upward flow of the circulating wastewater is zone 70 is faster than the downward flow of wastewater in zone 50, although the volume of wastewater in zone 50 is greater than the volume of liquid-gas mixture in zone 70.
  • the differential densities in zones 50, 70 provide sufficient movement and lifting force to maintain circulation, as indicated by the dashed arrows in Figure 10.
  • the elevated level of dissolved oxygen in the fluid injected via an array of nozzles 62 enhances the reaction between organic substances, dissolved oxygen, nutrients and microorganisms. [00115]
  • the reaction substantially takes place during circulation through zone 70, basin 42 and zone 50.
  • recovered aqueous phase from biomass extraction unit 90 may be recycled to retention chamber 80 and reactor 30 via lines 92, 93, 98, 102, and/or 41.
  • the reactor is configured substantially as illustrated in horizontal cross section in Figure 4B.
  • Reactor 330 includes two fast-flow zones 370a, 370b located on opposite sides of the reactor shaft 332.
  • One slow-flow zone 350 is disposed between the two fast-flow zones 270a, 270b.
  • This configuration may include two nozzle assemblies like assembly 60 disposed along opposite walls of the reactor, and may be advantageous for handling especially large volumes of oxygen-containing gas. In many cases, using one or more assembly 60 promotes enhanced gas to liquid transfer rates and permits effective gas injection control.
  • biofuel e.g., biodiesel, bioethanol, and biobutanol
  • algae e.g., biodiesel, bioethanol, and biobutanol
  • the essential factors for this reaction include water, carbon dioxide, minerals and light with the basic reaction as follows:
  • algae Light provided for algae must not be too strong nor too weak. After algae produce the desired products, they are harvested, and oil/fuel is extracted from their cell structure.
  • the method of oil extraction from algae may be any as known to one skilled in the art, such as mechanical crushing, chemical solvation, enzymatic extraction, expeller press, osmotic shock, supercritical fluid extraction, and ultrasonic-assisted extraction. ABE Fermentation
  • the above-described reactor assembly is also suitable for anaerobic ABE fermentation process, which is the production of acetone, butanol, and ethanol from starch, sugar, or other carbon-rich substrates.
  • An inert gas e.g., N 2
  • ABE fermentation usually uses a strain of bacteria from the Clostridium family, e.g., Clostridium acetobutylicum, Clostridium beijerinckii. Methane Production
  • the above-described reactor assembly is further suitable for the production of methane via biomass fermentation.
  • the digestion of biomass from manure, wastewater sludge, municipal solid waste (including landfills), or any other biodegradable feedstock is able to produce methane under anaerobic conditions.
  • An inert gas e.g., N 2
  • N 2 may be used as the gas lift in the deep shaft reactor to promote circulation and to facilitate mass transfer in the reactor to maximize production efficiency.
  • FIG 11 is a schematic of a deep shaft reactor system 20 according to an embodiment of this disclosure.
  • the deep shaft reactor system of this disclosure comprises a plurality of deep shaft reactor assemblies 1 arranged in series.
  • Each of the deep shaft reactor assemblies comprises a deep shaft reactor located at least mostly below ground level G.
  • Each of the deep shaft reactors has a diameter D and a depth L.
  • the shaft length may be up to 2000 feet (600m).
  • the diameter of the reactor may be up to 20 feet (6m).
  • deep shaft reactor system 20 comprises three deep shaft reactor assemblies IA, IB, and 1C. Fermentation feed gas comprising a first reactant concentration [Xl] is introduced by a fermentation feed gas inlet line 21a into a first reactor assembly IA of the series.
  • a first product gas produced within first reactor assembly IA and having a second reactant concentration [X2] is extracted from first reactor assembly IA and introduced as feed gas into the second reactor assembly IB of the series via a line 21b.
  • a second product gas produced within second reactor assembly IB and having a third reactant gas concentration [X3] is extracted from second reactor assembly IB and introduced as feed gas into a third reactor assembly 1C of the series via a line 21c.
  • any number of reactor assemblies 1 may be connected in series.
  • the deep shaft reactor system of this disclosure comprises 2 reactor assemblies; alternatively, 3 reactor assemblies in series; alternatively, any plural number of reactor assemblies aligned in series, with the product gas from subsequent reactor assemblies being introduced into the next reactor in the series until the last reactor of the series.
  • Product gas from the final deep shaft reactor in the series having a reactant gas concentration [X n ] is extracted via a final product gas line.
  • final product gas line 112 is utilized to extract final product gas having reactant gas concentration X f from the deep shaft reactor system.
  • first reactor assembly IA may contain a suspension comprising a first concentration of microorganisms [Ml] capable of operation in the presence of high reactant concentration, e.g. [Xl], of fermentation feed gas fed therein via initial fermentation feed gas inlet line 21a.
  • concentration of the reactant feed gas fed into the second reactor i.e. [X2] will be less than [Xl].
  • reactor assembly IB may comprise a deep shaft reactor containing a suspension comprising a second concentration [M2] of microorganisms which is less than [Ml].
  • reactor assembly 1C may comprise a deep shaft reactor containing a suspension comprising a third concentration [M3] of microorganisms which is less than [M2].
  • at least a portion of the product gas may be recycled to one or more of the reactor assemblies 1 to dilute the concentration of reactant in the gas fed into the reactor to which the product gas is recycled.
  • final product gas line 112 may be fluidly connected with one or more of inlet lines 21 for introduction of final product gas having gaseous reactant concentration [X f ] as diluent thereto.
  • lines 26a and 26b may connect product gas recycle line 26 with first reactor assembly inlet line 21a, and second reactor assembly inlet line 21b respectively.
  • Reactor assemblies 1 may comprise measurement apparatus whereby the concentration of gaseous reactant in the product gas may be determined. Should the concentration of reactant (e.g., carbon monoxide) in the product gas from any of the reactor assemblies be undesirably high, product gas may be recycled as diluent.
  • the concentration [X f ] of gaseous reactant in the final product gas extracted via line 112 may be maintained at a desired level.
  • a desired level may be, for example, a desired level of CO in the product gas during CO fermentation or the level of dissolved oxygen in the wastewater treatment fermentation system.
  • the desired level may be, in applications, essentially zero.
  • the high concentration fermentation feed gas fed into the first reactor assembly IA may be introduced into a subsequent reactor assembly of the series to increase the concentration of reactant fed into the reactor assembly to which the fermentation feed gas is introduced. That is, more concentrated feed gas may be provided to subsequent reactor assemblies if the product from the immediately previous reactor assembly does not have suitable reactant concentration to support fermentation/growth of microorganisms. For example, the concentration of reactant fed into the reactor assemblies may be increased until the concentration of reactant in the product gas just below the undesirable level. In this manner, maximum conversion of reactant by the microorganisms may be obtained/maintained.
  • high reactant concentration fermentation feed gas inlet line 21a to first reactor assembly IA of the series may be fluidly connected with second reactor assembly IB and third reactor assembly 1C via high reactant introduction lines 27a and 27b respectively.
  • each of the deep shaft reactors of reactor assemblies 1A-1C has the same depth L as the other reactors.
  • High feed gas concentration e.g., CO, CO 2 , 02, or other feed gas concentration
  • lower pressure reduced depth and thus reduced toxicity
  • the depth of the shaft to be used for a particular application is optimized based on the pressure sensitivity of any microorganism(s) to be used in the reactor, and such other factors as gaseous reactant or product toxicity at various pressures.
  • FIG. 12 is a schematic of a deep shaft reactor system 2OA for fermentation, in which reactor assemblies IA, IB, and 1C comprise deep shaft reactors having different depths.
  • first reactor assembly IA comprises a deep shaft reactor having a depth Ll
  • second reactor assembly IB comprises a deep shaft reactor having a depth L2
  • third reactor assembly 1C comprises a deep shaft reactor having a depth L3.
  • subsequent reactors in the series may have deeper depths, L, while still ensuring that the reactant gas concentration is not prohibitively toxic to the microorganism population therein.
  • the amount of reactant in the feed gas may be optimized during continuous operation of fermentation via the disclosed system.
  • the deep shaft reactor system may be operated to maximize biochemical reaction, for example, to ensure substantially 100% utilization of gaseous reactant.
  • first reactor assembly IA may be fed a fermentation feed gas via inlet line 21a having a feed gas concentration (e.g., an oxygen or CO concentration) [Xl], may contain a suspension comprising a microorganism concentration [Ml], and may have a vertical depth Ll;
  • second reactor assembly IB of the series may be fed a fermentation feed gas via line 21b having a feed gas concentration (gas exiting first reactor IA) having a CO concentration [X2], may contain a suspension comprising a microorganism concentration [M2], and may have a vertical depth Ll;
  • third reactor assembly 1C of the series may be fed a feed gas (gas exiting the second reactor IB) having a CO concentration [X3], may contain a suspension comprising a microorganism concentration [M3], and may have a vertical depth L3; and so on.
  • deep shaft reactor system 20 comprise a plurality of deep shaft reactor assemblies 1 aligned in series and fed with feed gas comprising gaseous reactant concentrations such that [X1]>[X2]>[X3], and so on.
  • deep shaft reactor system 20 comprises a plurality of reactor assemblies 1 aligned in series with L1 ⁇ L2 ⁇ L3, and so on.
  • deep shaft reactor system 20 comprises a plurality of deep shaft reactor assemblies 1 aligned in series, with the reactors operable with microorganism suspensions having concentrations [M1]>[M2]>[M3], and so on.
  • deep shaft reactor system 20 comprise a plurality of deep shaft reactor assemblies 1 aligned in series and operable such that [X1]>[X2]>[X3]... ; and [M1]>[M2]>[M3].
  • deep shaft reactor system 20 comprises a plurality of deep shaft reactor assemblies 1 aligned in series and operable such that [X1]>[X2]>[X3]... ; D1 ⁇ D2 ⁇ D3...; and [M1]>[M2]>[M3].
  • Deep shaft reactor system 20 is thus designed such that the pressure of operation, the concentration of biomass within each of a plurality of reactors, and/or the reactant content of the feed gas to each of a plurality of reactors of a plurality of reactor assemblies may be modified (i.e., the depth varied) to provide optimum conditions for bacterial fermentation.
  • Design of deep shaft reactor system 20 with a plurality of deep shaft reactors in series with various inlet concentrations of reactant gas in the fermentation feed gas and/or various depths allows manipulation of the optimum operating conditions (toxicity points) of the bacteria. Such serial design provides flexibility of operation.
  • serial design within a CO fermentation system may provide flexibility in operation when gasification of carbon- containing materials is utilized to provide the fermentation feed gas (i.e., the synthesis gas to be polished).
  • the fermentation feed gas i.e., the synthesis gas to be polished
  • the fermentation feed gas obtained therefrom will also vary.
  • synthesis gas may be produced from tires, trash, coal fines, etc., yielding synthesis gases having significantly varying composition. Being able to adjust the microorganism concentration and feed gas to each of the series of reactor assemblies within the disclosed deep shaft series enables optimum conversion of reactant to desired product.

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Abstract

La présente invention concerne un ensemble réacteur à cuve verticale qui comprend un réacteur incluant une cuve allongée et une tête fixée comportant un orifice d'admission de fluide, un orifice de sortie d'effluent et une tête. Ladite cuve comprend une zone de flux lent verticale présentant des première et seconde extrémités, et au moins une zone de flux rapide verticale adjacente à ladite zone de flux lent et dotée de première et seconde extrémités. Les premières extrémités sont en communication fluidique directe l'une avec l'autre, et les secondes extrémités sont en communication fluidique indirecte l'une avec l'autre par le biais de la tête. Le réacteur inclut en outre un ensemble d'injection gaz-liquide adjacent à, et en communication fluidique avec, la zone de flux rapide. L'ensemble réacteur inclut en outre une source de rayonnement. L'ensemble réacteur inclut par ailleurs une chambre d'enrichissement de réactif en communication fluidique avec ledit ensemble injection et une source d'alimentation en réactif.
PCT/US2009/060804 2008-11-12 2009-10-15 Systèmes de réacteur à cuve verticale WO2010056461A2 (fr)

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Cited By (4)

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EP3211065A1 (fr) * 2016-02-25 2017-08-30 Linde Aktiengesellschaft Procédé et système de dosage co2 pour cultiver des algues
WO2018132379A1 (fr) * 2017-01-10 2018-07-19 Calysta, Inc. Réacteurs de fermentation alimentés par gaz, systèmes et procédés utilisant une zone d'écoulement verticale
US10538730B2 (en) 2016-06-17 2020-01-21 Calysta, Inc. Gas-fed fermentation reactors, systems and processes
US10689610B2 (en) 2017-08-14 2020-06-23 Calysta, Inc. Gas-fed fermentation reactors, systems and processes utilizing gas/liquid separation vessels

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WO1993000159A1 (fr) * 1991-06-24 1993-01-07 Henkel Kommanditgesellschaft Auf Aktien Reacteur a puits unique et son utilisation
DE4427843C1 (de) * 1994-07-28 1996-01-18 Mannesmann Ag Tiefschachtreaktor
US6010667A (en) * 1995-02-16 2000-01-04 Buehler Ag Shaft reactor for treating bulk material
US20040076555A1 (en) * 2000-11-02 2004-04-22 Viktor Wagner Shaft reactor comprising a gassed discharge cone

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WO1993000159A1 (fr) * 1991-06-24 1993-01-07 Henkel Kommanditgesellschaft Auf Aktien Reacteur a puits unique et son utilisation
DE4427843C1 (de) * 1994-07-28 1996-01-18 Mannesmann Ag Tiefschachtreaktor
US6010667A (en) * 1995-02-16 2000-01-04 Buehler Ag Shaft reactor for treating bulk material
US20040076555A1 (en) * 2000-11-02 2004-04-22 Viktor Wagner Shaft reactor comprising a gassed discharge cone

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3211065A1 (fr) * 2016-02-25 2017-08-30 Linde Aktiengesellschaft Procédé et système de dosage co2 pour cultiver des algues
US10538730B2 (en) 2016-06-17 2020-01-21 Calysta, Inc. Gas-fed fermentation reactors, systems and processes
US10570364B2 (en) 2016-06-17 2020-02-25 Calysta, Inc. Gas-fed fermentation reactors, systems and processes
US11332706B2 (en) 2016-06-17 2022-05-17 Calysta, Inc. Gas-fed fermentation reactors, systems and processes
WO2018132379A1 (fr) * 2017-01-10 2018-07-19 Calysta, Inc. Réacteurs de fermentation alimentés par gaz, systèmes et procédés utilisant une zone d'écoulement verticale
CN110382681A (zh) * 2017-01-10 2019-10-25 凯利斯塔公司 利用垂直流动区的进气发酵反应器、系统和方法
US11795428B2 (en) 2017-01-10 2023-10-24 Calysta, Inc. Gas-fed fermentation reactors, systems and processes utilizing a vertical flow zone
US10689610B2 (en) 2017-08-14 2020-06-23 Calysta, Inc. Gas-fed fermentation reactors, systems and processes utilizing gas/liquid separation vessels
US11034930B2 (en) 2017-08-14 2021-06-15 Calysta, Inc. Gas-fed fermentation reactors, systems and processes utilizing gas/liquid separation vessels
US11572539B2 (en) 2017-08-14 2023-02-07 Calysta, Inc. Gas-fed fermentation reactors, systems and processes utilizing gas/liquid separation vessels
US11939567B2 (en) 2017-08-14 2024-03-26 Calysta, Inc. Gas-fed fermentation reactors, systems and processes utilizing gas/liquid separation vessels

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