Toray unveils breakthrough bioreactor promising massive energy savings

The technology can be customized for diverse chemicals by adjusting both the microorganisms and reactor structure

Toray Industries has claimed to have developed a groundbreaking immobilized-microorganism bioreactor technology that could slash energy use by 80% to 90%, dramatically cutting operational costs while reducing environmental impact. 

The innovative system “immobilizes specific microorganisms on wood-based carriers and packs them into a reactor,” allowing “ongoing contact between an aqueous solution containing the target chemical and a packed bed [so] microbial enzymes [can] convert the target substance efficiently into a desired product.” 

In a recent in-house trial using acrylonitrile, the technology achieved conversion rates exceeding 99.5%, producing valuable chemicals such as acrylic, propionic, acetic, and other organic acids.  

When combined with activated-sludge treatment, these products “can be completely broken down to carbon dioxide.” The sealed reactor also “reduces losses from airborne dispersion and improves safety,” making it particularly effective for volatile substances. 

Toray says the technology can be customized for diverse chemicals by adjusting both the microorganisms and reactor structure. The company plans to “step up technical verification and operational design at internal and external production sites to commercialize this technology as a new energy-conserving solution.” 

Toray added that it will “continue to tackle environmental challenges and contribute to a sustainable economy through its materials technologies.”