Toray Industries, Inc. announced the development of an immobilized-microorganism bioreactor technology that promises to transform chemical conversion processes. The company estimates that this technology can reduce energy consumption by 80–90% compared to conventional high-temperature, high-pressure methods, significantly cutting operational costs while lowering environmental impact.
How the Technology Works
The technology packs wood-based carriers coated with specific microorganisms into a reactor. As an aqueous solution containing the target chemical flows through the packed bed, microbial enzymes efficiently convert the substance into desired products.
In in-house demonstration trials using acrylonitrile, the reactor achieved conversion rates exceeding 99.5%. The technology produces chemicals such as acrylic, propionic, and acetic acids, and activated-sludge treatment fully breaks them down into carbon dioxide.
The reactor’s tightly sealed design enhances safety and minimizes losses from volatile substances, making it especially suitable for chemicals prone to airborne dispersion.
Versatile Applications Across Chemicals
By adjusting the immobilized microorganisms on the carriers and optimizing the reactor design, Toray applies the technology to a wide range of chemical substances. Toray maintains a library of approximately 500 microbial species, allowing for tailored solutions for both environmental remediation and production of valuable chemicals.
Key Features and Advantages
*Customizable: Microorganisms and reactor structures can be selected based on target chemicals and site-specific conditions.
*High Efficiency: Optimized microorganism-carrier combinations achieve over 99.5% conversion for acrylonitrile and handle volatile substances safely.
*Energy-Saving and Safe: The process eliminates the need for heating or pressurization, reducing energy consumption while enhancing operational safety.
Next Steps Toward Commercialization
Toray plans to intensify technical verification and refine operational design at both internal and external production sites. As per the press release, the company aims to commercialize this energy-conserving bioreactor technology as part of its broader commitment to tackling environmental challenges and promoting a sustainable economy through advanced materials and process innovations.
