Fermentation hydrocarbon gas products separation via membrane

Abstract

Disclosed herein is a process for separation and purification of a fermentation gas product from a fermenter off-gas containing a fermentation product, volatile impurities, bio-product impurities and water, based on a membrane system. In one preferred embodiment of the present invention, the process of separating and purifying a fermentation product from a fermenter off-gas, containing the fermentation product, volatile impurities, bio-byproduct impurities and water, comprises the steps of: (a) compressing the fermenter off-gas and feeding it into a membrane module, and (b) selectively permeating the volatile impurities, bio-byproduct impurities and water through the membrane, resulting in a product rich retentate stream. The fermentation gas product is separated from the fermenter off-gas in a single membrane stage to produce a purified retentate stream. In accordance with this embodiment of the invention, the fermenter off-gas (2), comprising the fermentation gas product, volatile impurities, bio-byproduct impurities and water, passes through a blower (201) that transports it to a gas holder (202), in order to smooth the process fluctuations. Stream (11) exits the gas holder (202) and is compressed in a multi-stage compressor (203), from which bio-byproduct and water are removed through stream (4). The compressed stream (12) enters the membrane module (204), which permeates the volatile impurities, disposing them in stream (13). The process may be still conducted in a 2-stage membrane system in accordance with the present invention.

Claims

1. A method of separating and purifying a fermentation product directly from a fermenter off-gas containing the fermentation product, volatile impurities and bio-byproduct impurities, comprising the steps of: (a) compressing the fermenter off-gas to produce a compressed off-gas on a multi-stage compressor system wherein the bio-byproduct impurities and water are removed, and feeding the compressed off-gas into at least one membrane module comprising a membrane, and (b) selectively permeating the volatile impurities through the membrane, resulting in a retentate stream rich in the fermentation product.

2. The method of claim 1, wherein the fermentation product comprises a compound selected from the group consisting of ethylene, propylene, isobutylene, 1-butene, 1,3-butadiene and isoprene.

3. The method of claim 1, wherein the volatile impurities comprise one or more compounds selected from the group consisting of H.sub.2O, CO.sub.2, N.sub.2 and O.sub.2.

4. The method of claim 3, wherein the volatile impurities comprise about 30 to about 80 mol % CO.sub.2, and about 1 to about 20 mol % H.sub.2O.

5. The method of claim 3, wherein the volatile impurities comprise about 5 to about 70 mol % CO.sub.2, about 1 to about 20 mol % H.sub.2O, about 40 to about 95 mol % N.sub.2, and about 0.5 to about 15 mol % O.sub.2.

6. The method of claim 1, wherein the bio-byproduct impurities comprise a polar impurity.

7. The method of claim 6, wherein the bio-byproduct impurities comprise a compound selected from the group consisting of ethanol, acetone, methanol, acetaldehyde, methacrolein, methyl vinyl ketone, 3-methylfuran, 2-methyl-2-vinyloxirane, cis- and trans-3-methyl-1,3-pentadiene, a C5 prenyl alcohol, 2-heptanone, 6-methyl-5-hepten-2-one, 2,4,5-trimethylpyridine, 2,3,5-trimethylpyrazine, citronellal, methanethiol, methyl acetate, 1-propanol, diacetyl, 2-butanone, 2-methyl-3-buten-2-ol, ethyl acetate, 2-methyl-1-propanol, 3-methyl-1-butanal, 3-methyl-2-butanone, 1-butanol, 2-pentanone, 3-methyl-1-butanol, ethyl isobutyrate, 3-methyl-2-butenal,butyl acetate, 3-methylbutyl acetate, 3-methyl-3-buten-1-yl acetate, 3-methyl-2-buten-1-yl acetate, (E)-3,7-dimethyl-1,3,6-octatriene, (Z)-3,7-dimethyl-1,3,6-octatriene, (E,E)-3 ,7,11-trimethyl-1,3,6,10-dodecatetraene, (E)-7,11-dimethyl-3-methylene-1,6,10-dodecatriene, 3-hexen-1-ol, 3-hexen-1-yl acetate, limonene, geraniol (trans-3,7-dimethyl-2,6-octadien-1-ol), and citronellol (3,7-dimethyl-6-octen-1-ol).

8. The method of claim 1, wherein the membrane module comprises a membrane material selected from the group consisting of polyacetylene, poly(ethylene oxide), polysulfone, polyethersulfone, styrenic polymers and copolymers, polycarbonates, cellulosic polymers, polyamides, polyimides, polyethers, polyarylates, poly(arylene ether), poly(arylene oxide), poly(phenylene oxide), poly(pyrrolone), polyurethanes, polyesters, polyacrylates, polysulfides, polyolefins, polyvinyls, polyvinyl esters, and mixtures thereof.

9. The method of claim 1, wherein said compressing the fermenter off-gas takes place in a multi-stage compressor system operated at a compressor outlet pressure of about 5 to about 25 bar.

10. The method of claim 1, wherein the volatile impurities are permeated through the membrane at a pressure of about 0.1 to about 10 bar.

11. The method of claim 1, wherein the purity of the retentate stream rich in the fermentation product is 70 wt % or greater.

12. The method of claim 11, wherein the retentate stream rich in the fermentation product is further purified with an adsorption system.

13. The method of claim 11, wherein the retentate stream rich in the fermentation product is further purified with a cryogenic distillation system.

14. The method of claim 11, wherein the retentate stream rich in the fermentation product is further purified with a solvent extraction system.

15. The method of claim 14, wherein the solvent extraction system comprises a solvent, and the solvent comprises a hydrocarbon selected from the group consisting of C.sub.11 through C.sub.13 hydrocarbons.

16. A method of separating and purifying a fermentation product directly from a fermenter off-gas containing the fermentation product, volatile impurities and bio-byproduct impurities, comprising the steps of: (a) compressing the fermenter off-gas on a multi-stage compressor system wherein the bio-byproduct impurities and water are removed, and feeding the compressed off-gas into a first membrane stage, (b) selectively permeating the volatile impurities through the first membrane stage and obtaining a fermentation product rich retentate stream, (c) compressing a permeate stream from the first membrane stage on a multi-stage compressor system, (d) selectively permeating the volatile impurities through a second membrane stage comprising a membrane to produce a second retentate stream and, (e) recycling the retentate stream from the second membrane stage to the first membrane stage.

17. The method of claim 16, wherein the fermentation product comprises a compound selected from the group consisting of ethylene, propylene, isobutylene, 1-butene, 1,3- butadiene and isoprene.

18. The method of claim 16, wherein the volatile impurities comprise one or more compounds selected from the group consisting of H.sub.2O, CO.sub.2, N.sub.2 and O.sub.2.

19. The method of claim 18, wherein the volatile impurities comprise about 30 to about 80 mol % CO.sub.2, and about 1 to about 20 mol % H.sub.2O.

20. The method of claim 18, wherein the volatile impurities comprise about 5 to about 70 mol % CO.sub.2, about 1 to about 20 mol % H.sub.2O, about 40 to about 95 mol % N.sub.2, and about 0.5 to about 15 mol % O.sub.2.

21. The method of claim 16, wherein the bio-byproduct impurities comprise a polar impurity.

22. The method of claim 21, wherein the bio-byproduct impurities comprise one or more compounds selected from the group consisting of ethanol, acetone, methanol, acetaldehyde, methacrolein, methyl vinyl ketone, 3-methylfuran, 2-methyl-2-vinyloxirane, cis- and trans-3-methyl-1,3-pentadiene, a C5 prenyl alcohol, 2-heptanone, 6-methyl-5-hepten-2-one, 2,4,5-trimethylpyridine, 2,3,5-trimethylpyrazine, citronellal, methanethiol, methyl acetate, 1-propanol, diacetyl, 2-butanone, 2-methyl-3-buten-2-ol, ethyl acetate, 2-methyl-1-propanol, 3-methyl-1-butanal, 3-methyl-2-butanone, 1-butanol, 2-pentanone, 3-methyl-1-butanol, ethyl isobutyrate, 3-methyl-2-butenal, butyl acetate, 3-methylbutyl acetate, 3-methyl-3-buten-1-yl acetate, 3-methyl-2-buten-1-yl acetate, (E)-3,7-dimethyl-1,3,6-octatriene, (Z)-3,7-dimethyl-1,3,6-octatriene, (E,E)-3,7,11-trimethyl-1,3,6,10-dodecatetraene, (E)-7,11-dimethyl-3-methylene-1,6,10-dodecatriene, 3-hexen-1-ol , 3-hexen-1-yl acetate, limonene, geraniol (trans-3,7-dimethyl-2,6-octadien-1-ol), and citronellol (3,7-dimethyl-6-octen-1-ol).

23. The method of claim 16, wherein the first membrane stage or the second membrane stage comprises a membrane material selected from the group consisting of polyacetylene, poly(ethylene oxide), polysulfone, polyethersulfone, styrenic polymers and copolymers, polycarbonates, cellulosic polymers, polyamides, polyimides, polyethers, polyarylates, poly(arylene ether), poly(arylene oxide), poly(phenylene oxide), poly(pyrrolone), polyurethanes, polyesters, polyacrylates, polysulfides, polyolefins, polyvinyls, polyvinyl esters, and mixtures thereof.

24. The method of claim 16, wherein said compressing the permeate stream from the first membrane stage on a multi-stage compressor system is performed at a compressor outlet pressure of about 5 to about 25 bar.

25. The method of claim 16, wherein the volatile impurities are permeated through the second membrane stage at a pressure of about 0.1 to about 10 bar.

26. The method of claim 16, wherein the purity of the fermentation product rich retentate stream is 90 wt % or greater.

27. The method of claim 26, wherein the fermentation product rich retentate stream is further purified with a cryogenic distillation system.

28. The method of claim 26, wherein the fermentation product rich retentate stream is further purified with a solvent extraction system.

29. The method of claim 28, wherein the solvent extraction system comprises a solvent, and the solvent comprises a hydrocarbon selected from the group consisting of C.sub.11 through C.sub.13 hydrocarbons.

30. The method of claim 16, wherein the fermentation product rich retentate stream is further purified with an adsorption system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a single stage membrane for fermentation gas product separation.

(2) FIG. 2 is a fermentation gas product separation via 2-stage membranes with product being the retentate from the first membrane step.

(3) FIG. 3 is a fermentation gas product separation via 2-stage membranes with product being the retentate from the second membrane step.

(4) FIG. 4 is a fermentation gas product separation via 2-stage membranes with product being the retentate from the second membrane step, alternate embodiment.

(5) FIG. 5 is a fermentation gas product separation with 3 membranes ordered in series and with recycle.

DETAILED DESCRIPTION OF THE INVENTION

(6) The present invention is a process for separating impurities from the hydrocarbon gaseous product from a fermentation process to produce a fermentation hydrocarbon gas product using membranes.

(7) The gaseous stream comprises a fermenter off-gas comprising the fermentation hydrocarbon gas product, volatiles impurities, bio-byproduct impurities and water.

(8) The fermentation hydrocarbon gas product (or fermentation product) comprises a hydrocarbon gaseous compound produced in a fermentation process. Preferably, the fermentation hydrocarbon gas product is selected from the group consisted of ethylene, propylene, isobutylene, 1-butene, butadiene and isoprene. More preferably, the fermentation hydrocarbon gas is butadiene.

(9) The fermentation hydrocarbon gas product can be obtained by aerobic or anaerobic fermentation process. When the fermentation is anaerobic, the volatile impurities can comprise H.sub.2O and CO.sub.2, wherein the volatile impurities comprises about 30 to about 80 mol % CO.sub.2, and about 1 to about 20 mol % H.sub.2O. When the fermentation is aerobic, the volatile impurities can comprise H.sub.2O, CO.sub.2, N.sub.2 and O.sub.2, wherein the volatile impurity comprises about 5 to about 70 mol % CO.sub.2, about 1 to about 20 mol % H.sub.2O, about 40 to about 95 mol % N.sub.2, and about 0.5 to about 15 mol % O.sub.2.

(10) The bio-byproduct impurity comprises a polar impurity that can be selected from the group consisting of ethanol, acetone, methanol, acetaldehyde, methacrolein, methyl vinyl ketone, 3-methylfuran, 2-methyl-2-vinyloxirane, cis- and trans-3-methyl-1,3-pentadiene, a C5 prenyl alcohol (such as 3-methyl-3-buten-1-ol or 3-methyl-2-buten-1-ol), 2-heptanone, 6-methyl-5-hepten-2-one, 2,4,5 -trimethylpyridine, 2,3,5-trimethylpyrazine, citronellal, methanethiol, methyl acetate, 1-propanol, diacetyl, 2-butanone, 2-methyl-3-buten-2-ol, ethyl acetate, 2-methyl-1-propanol, 3-methyl-1-butanal, 3-methyl-2-butanone, 1-butanol, 2-pentanone, 3-methyl-1-butanol, ethyl isobutyrate, 3-methyl-2-butenal, butyl acetate, 3-methylbutyl acetate, 3-methyl-3-buten-1-yl acetate, 3-methyl-2-buten-1-yl acetate, (E)-3,7-dimethyl-1,3,6-octatriene, (Z)-3,7-dimethyl-1,3,6-octatriene, (E,E)-3,7,11-trimethyl-1,3,6,10-dodecatetraene, (E)-7,11-dimethyl-3-methylene-1,6,10-dodecatriene, 3-hexen-1-ol, 3-hexen-1-yl acetate, lmonene, geraniol (trans-3,7-dimethyl-2,6-octadien-1-ol), and citronellol (3,7-dimethyl-6-octen-1-ol).

(11) The term membrane as used herein is intended to encompass a wide variety of possible configurations known in the prior art. For example, the membrane may be used as a flat film, tubular film or hollow fiber.

(12) The membrane material can be based on a wide range of polymers, such as polyacetylene, poly(ethylene oxide), polysulfone, polyethersulfone, styrenic polymers and copolymers, polycarbonates, cellulosic polymers, polyamides, polyimides, polyethers, polyarylates, poly(arylene ether), poly(arylene oxide), poly(phenylene oxide), poly(pyrrolone), polyurethanes, polyesters, polyacrylates, polysulfides, polyolefins, polyvinyls and polyvinyl esters. Mixture of these polymers can be used as well.

(13) Other subsequent purification procedures, such as cryogenic distillation, organic solvent extraction or by using an adsorption system, may also be adopted. When a solvent extraction is performed, the solvent can be selected from the group comprising C11 through C13 hydrocarbons.

(14) In a first preferred embodiment of the present invention, the process of separating and purifying a fermentation hydrocarbon product from a fermenter off-gas, containing the fermentation hydrocarbon product, volatile impurity, bio-byproduct impurity and water, comprises the steps of: (a) compressing the fermenter off-gas and feeding it into a membrane module, and (b) selectively permeating the volatile impurity, bio-byproduct impurity and water through the membrane, resulting in a hydrocarbon product rich retentate stream. This embodiment is shown of FIG. 1 wherein the fermentation hydrocarbon gas product is separated from the fermenter off-gas in a single membrane stage to produce purity purified retentate stream.

(15) In accordance with this first embodiment of the invention and referring to FIG. 1, the fermenter off-gas 2, comprising the fermentation hydrocarbon gas product, volatile impurities, bio-byproduct impurities and water, passes through a blower 201 that transports it via stream 10 to a gas holder 202, in order to smooth the process fluctuations.

(16) Stream 11 exits the gas holder 202 and is compressed in a multi-stage compressor 203, from which bio-byproduct and water are removed through stream 4. The compressed stream 12 enters the membrane module 204, which permeates the volatile impurities, disposing them in stream 13.

(17) The retentate stream 5 may pass through further purification processes (not shown in the FIG. 1), which can comprise an adsorption system, cryogenic distillation or extraction via solvent or a combination thereof. The purity of the product stream 5 is about 70% wt or greater.

(18) In a second preferred embodiment of the present invention, the process of separation and purifying a fermentation product from a fermenter off-gas, containing the fermentation hydrocarbon product, volatile impurity, bio-byproduct impurity and water, comprises the steps of: (a) compressing the fermenter off-gas and feeding it into a first membrane stage, (b) selectively permeating the volatile impurity, bio-byproduct impurity and water through the first membrane stage and obtaining a fermentation hydrocarbon product rich retentate stream, (c) compressing the permeate stream from the first membrane stage, (d) selectively permeating the volatile impurity, bio-byproduct impurities and water through the second membrane stage and, (e) recycling the retentate stream from the second membrane stage to the first membrane stage.

(19) FIG. 2 illustrates the second preferred embodiment of the invention, wherein the fermentation gas product is separated from the fermenter off-gas in a 2-stage membrane system to produce purified fermentation gas product as the retentate stream from the first membrane stage.

(20) The fermenter off-gas 2, comprising fermentation hydrocarbon gas product, volatile impurities, bio-byproduct impurities and water, passes through a blower 201 and is fed via stream 10 to a gas holder 202, to smooth process fluctuations.

(21) Stream 11 exits the gas holder 202 and is compressed in a multi-stage compressor 203, from which bio-byproduct and water are removed through stream 4. The compressed stream 12 enters the first membrane stage 204, which permeates the volatile impurities. The permeate stream 14 is then compressed in the multi-stage compressor 205 and sent through stream 15 to the second membrane stage 206. Volatile impurities are permeated by the membrane and disposed by stream 13. Stream 16, still containing the fermentation hydrocarbon gas product, passes through a compressor (not shown) and is recycled to membrane 204.

(22) This membrane configuration is capable of reaching a high purity fermentation hydrocarbon product (90 wt %) in stream 5. The stream 5 may pass through further purification processes (not shown in the figure), which can comprise an adsorption system, cryogenic distillation or extraction via solvent or combination thereof. The purity of the product retentate stream 5 is about 90 wt % or greater.

(23) In a third preferred embodiment of the present invention, the process of separation and purifying a fermentation hydrocarbon product from a fermenter off-gas, containing the fermentation hydrocarbon product, volatile impurity, bio-byproduct impurity and water, comprises the steps of: (a) compressing the fermenter off-gas and feeding it into a first membrane stage, (b) selectively permeating the volatile impurity, bio-byproduct impurity and water through the first membrane stage and obtaining a fermentation hydrocarbon product rich retentate stream, (c) selectively permeating the retentate through the second membrane stage and, (d) recycling the permeate stream from the second membrane stage to the first membrane stage.

(24) FIG. 3 illustrates the third embodiment of the invention, wherein the fermentation hydrocarbon gas product is separated from the fermenter off-gas in a 2-stage membrane system, with recycle, to produce high purity fermentation hydrocarbon product in the retentate stream from the second membrane stage.

(25) The fermenter off-gas 2, comprising fermentation hydrocarbon gas product, volatile impurities, bio-byproduct impurities and water, passes through a blower 201 and is fed via stream 10 to a gas holder 202 to smooth the process fluctuations.

(26) Stream 11 exits the gas holder 202 and is compressed in a multi-stage compressor 203, from which bio-byproduct and water are removed through stream 4. The compressed stream 12 enters the first membrane stage 204, which permeates the volatile impurities, disposing them through stream 13. The retentate stream 14 is sent to the second membrane stage 206. The permeate stream 15 then passes through the multi-stage compressor 205 and is recycled to membrane 204.

(27) The retentate 5 may pass through further purification processes (not shown in the FIG. 3), which can comprise an adsorption system, cryogenic distillation or extraction via solvent or combination thereof, producing the high purity fermentation gas product in stream 5.

(28) FIG. 4 and FIG. 5 represent other possible configurations of the invention, in which 201 is a blower, 10 is a stream, 202 is a gas holder, 203 is a multi-stage compression stage and 204, 205 and 206 (stream 18 exiting stage 206) are membrane stages. Other configurations different from the examples shown can be adopted with multiple membrane and compression stages, which are not intended to limit the scope or underlying principles of the invention in any way.

(29) As the retentate stream passes from one membrane to another, it will contain higher purity of the product than it had before and the permeate stream, higher impurity percentage.

(30) The number of membrane modules to compose the system depends on the final purity required and the maximum losses allowed.

(31) Compressors can be used to ensure the differential pressure at any membrane step. The compressor outlet pressure is about 5 to about 25 bar, preferentially about 8 to about 15 bar. The membrane permeate pressure is about 0.1 to about 10 bar, preferentially about 1 to about 5 bar.

EXAMPLE

(32) Butadiene (fermentation gas product) is separated from the fermenter off-gas comprising 31.9% wt of butadiene, 61.9% wt of CO.sub.2, 5 ppm wt/wt of 1,4-butanediol, and 6.3% wt of water in a 2-stage membrane system, according (FIG. 2) to produce purified butadiene (99.99% wt).

(33) The fermenter off-gas 2 (temperature=37.5 C. and p=1 atm), comprising butadiene, CO.sub.2, 1,4-butanediol and water, passes through a blower 201 and is fed to a gas holder 202, to smooth process fluctuations. Stream 11 exits the gas holder 202 and is compressed in a multi-stage compressor 203, from which 1,4-butanediol and water are removed through stream 4. The compressed stream 12 (35.9% wt of butadiene, 62.1% wt of CO.sub.2 and 2.1% wt of water), enters the first membrane stage 204 at T=96.5 C. and p=10 bar, which permeates the volatile impurities. The permeate stream 14 is then compressed in the multi-stage compressor 205 and sent through stream 15 to the second membrane stage 206 at T=116.2 C. and p=10 bar. Volatile impurities are permeated by the membrane and disposed by stream 13. Stream 16, still containing the butadiene, passes through a compressor (not shown) and is recycled to membrane 204.

(34) In order to obtain a butadiene stream with 99.99% wt of purity, with a membrane with CO.sub.2 permeability of 65.5 Barrer and Butadiene permeability of 4.2 Barrer leading to a CO.sub.2/Butadiene selectivity of 15.6, the membrane area required is 46,000 m.sup.2 for the first stage and 2,640 m.sup.2 for the second stage. Selecting a membrane with CO.sub.2 permeability of 210 Barrer and Butadiene permeability of 4.2 Barrer leading to a CO.sub.2/Butadiene selectivity of 50, the membrane area required is 5,000 m.sup.2 for the first stage and 1,800 m.sup.2 for the second stage.

(35) In order to obtain a butadiene stream with 90,00% wt of purity, with a membrane with CO.sub.2 permeability of 65.5 Barrer and Butadiene permeability of 4.2 Barrer leading to a CO.sub.2/Butadiene selectivity of 15.6, the membrane area required is 11,680 m.sup.2 for the first stage and 2,200 m.sup.2 for the second stage. Selecting a membrane with CO.sub.2 permeability of 210 Barrer and Butadiene permeability of 4.2 Barrer leading to a CO.sub.2/Butadiene selectivity of 50, the membrane area required is 1,600 m.sup.2 for the first stage and 800 m.sup.2 for the second stage.

INDUSTRIAL APPLICABILITY

(36) The present invention pertains fundamentally to the field of separation and purification of purification of a hydrocarbon gas product, produced by fermentation.