U.S. patent application number 13/784445 was filed with the patent office on 2013-10-24 for methods and systems for processing lignocellulosic materials and related compsitions.
This patent application is currently assigned to VIRDIA LTD. The applicant listed for this patent is VIRDIA LTD.. Invention is credited to Aharon EYAL, Robert P. JANSEN, Philippe LAVIELLE.
Application Number | 20130276778 13/784445 |
Document ID | / |
Family ID | 46020259 |
Filed Date | 2013-10-24 |
United States Patent
Application |
20130276778 |
Kind Code |
A1 |
JANSEN; Robert P. ; et
al. |
October 24, 2013 |
Methods and Systems for Processing Lignocellulosic Materials and
Related Compsitions
Abstract
A method comprising: (a) providing a lignocellulosic substrate;
(b) contacting said lignocellulosic substrate with an extractant
comprising a water-soluble organic solvent to form an extracted
substrate and a miscella; (c) removing miscella from said extracted
substrate; and (d) hydrolyzing said extracted substrate using a
chemically catalyzed process.
Inventors: |
JANSEN; Robert P.;
(Woodcrest Drive, IL) ; EYAL; Aharon; (Jerusalem,
IL) ; LAVIELLE; Philippe; (Burlingame, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VIRDIA LTD. |
Herzelia |
|
IL |
|
|
Assignee: |
VIRDIA LTD
Herzelia
IL
|
Family ID: |
46020259 |
Appl. No.: |
13/784445 |
Filed: |
March 4, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13316327 |
Dec 9, 2011 |
8404355 |
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13784445 |
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61474298 |
Apr 12, 2011 |
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61524350 |
Aug 17, 2011 |
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61528257 |
Aug 28, 2011 |
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61533078 |
Sep 9, 2011 |
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61539196 |
Sep 26, 2011 |
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61539239 |
Sep 26, 2011 |
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61539272 |
Sep 26, 2011 |
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61539854 |
Sep 27, 2011 |
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61539861 |
Sep 27, 2011 |
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61552402 |
Oct 27, 2011 |
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61559529 |
Nov 14, 2011 |
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61562931 |
Nov 22, 2011 |
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Current U.S.
Class: |
127/1 ; 127/29;
127/37 |
Current CPC
Class: |
Y10T 428/31982 20150401;
B01J 2219/00006 20130101; C08B 15/00 20130101; C12P 2201/00
20130101; C08H 8/00 20130101; C13K 1/02 20130101 |
Class at
Publication: |
127/1 ; 127/29;
127/37 |
International
Class: |
C08B 15/00 20060101
C08B015/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 9, 2010 |
IL |
IL 209912 |
Dec 21, 2010 |
IL |
IL 210161 |
Claims
1. A method comprising: (a) providing a lignocellulosic substrate;
(b) contacting said lignocellulosic substrate with an extractant
comprising a water-soluble organic solvent to form an extracted
substrate and a miscella; (c) removing miscella from said extracted
substrate; and (d) hydrolyzing said extracted substrate using a
chemically catalyzed process.
2. A method according to claim 1, wherein said hydrolyzing employs
a mineral acid as a catalyst.
3. A method according to claim 2, wherein said mineral acid
includes HCl.
4. A method according to claim 2, wherein said mineral acid
includes H.sub.2SO.sub.4.
5. A method according to claim 1, wherein said hydrolyzing employs
a reactive fluid as a catalyst.
6. A method according to claim 1 comprising: (a) filtering lignin
solids from hydrolyzate formed by said hydrolyzing, wherein a
filtration rate of said filtering is faster by at least 10%
compared with a filtration rate of lignin solids from hydrolyzate
formed by hydrolyzing without said extracting, using an identical
filter and identical filtration conditions.
7. A method according to claim 6, wherein said hydrolyzing employs
a mineral acid as a catalyst.
8. A method according to claim 7, wherein said mineral acid
includes HCl.
9. A method according to claim 7 wherein said mineral acid includes
H.sub.2SO.sub.4.
10. A method according to claim 6, wherein said hydrolyzing employs
a reactive fluid as a catalyst.
11. A system comprising, (a) an extraction module adapted to
extract a lignocellulosic substrate with an extractant comprising a
water soluble organic solvent and a weak acid, and to output an
extracted substrate and a miscella; and (b) a hydrolysis module
adapted to receive said extracted substrate and to contact it with
hydrochloric acid at a concentration of at least 30% to produce an
acid hydrolyzate.
12. A system according to claim 11, comprising a dryer adapted to
remove extractant from said extracted substrate.
13. A system according to claim 11, comprising a disruption module
adapted to apply a predetermined pressure-temperature-time profile
to said substrate to produce a disrupted substrate.
14. A system according to claim 13, wherein said disruption module
includes at least one item selected from the group consisting of a
plug screw feeder and a steam explosion reactor.
15. A system according to claim 11, comprising one or more
distillation columns adapted to receive and process said miscella
and return at least a portion of said solvent to said extraction
module.
16. A system according to claim 11, comprising a methane generator
adapted to obtain said hydrocarbon comprising an aqueous phase.
17. A lignocellulosic composition comprising (on a dry matter
basis) cellulose, hemicellulose and lignin and characterized by at
least two characteristic selected from the group consisting of: (i)
less than 5000 PPM lipophilic material; (ii) less than 5000 PPM
ash; (iii) less than 2000 PPM Ca; (iv) less than 10,000 PPM pectin;
(v) less than 2000 PPM furfural; (vi) at least 10 PPM of a marker
selected from furfural, organically bound sulfur and a water
soluble solvent; and (vii) a moisture content of 5 to 30%.
18. A lignocellulosic composition according to claim 17,
characterized by at least three characteristics selected from said
group.
19. A lignocellulosic composition according to claim 17,
characterized by at least four characteristics selected from said
group.
20. A lignocellulosic composition according to claim 17,
characterized by at least five characteristics selected from said
group.
Description
CROSS-REFERENCE
[0001] This application claims priority under 35 USC 120 as a
continuation of U.S. Ser. No. 13/316,327, filed Dec. 9, 2011, which
claims priority under 35 U.S.C. .sctn.119(a) and/or .sctn.365(b)
to:
[0002] IL209912 entitled "A METHOD FOR TREATING A LIGNOCELLULOSIC
FEED CONTAINING ASH AND FATTY ACID" to Aharon EYAL et al. filed on
Dec. 9, 2010; and
[0003] IL210161 entitled "A METHOD FOR PROCESSING A LIGNOCELLULOSIC
MATERIAL INTO A HYDROLYZATE PRODUCT" to Aharon EYAL filed on Dec.
21, 2010; each of which is fully incorporated herein by reference;
and
[0004] in accord with the provisions of 35 U.S.C. .sctn.119(e) and
.sctn.363, this application claims the benefit of the following
U.S. Provisional Patent Applications:
[0005] U.S. 61/474,298 entitled "A METHOD FOR PREPARING A
HYDROLYZATE" to Robert JANSEN et al. filed on Apr. 12, 2011;
[0006] U.S. 61/524,350 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Aharon EYAL et al. filed on Aug. 17,
2011; and
[0007] U.S. 61/528,257 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Aug.
28, 2011.
[0008] U.S. 61/533,078 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Sep. 9,
2011;
[0009] U.S. 61/539,196 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Sep.
26, 2011;
[0010] U.S. 61/539,239 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Sep.
26, 2011;
[0011] U.S. 61/539,272 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Sep.
26, 2011;
[0012] U.S. 61/539,854 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Sep.
27, 2011;
[0013] U.S. 61/539,861 entitled "A METHOD FOR PROCESSING A
LIGNOCELLULOSIC MATERIAL INTO A HYDROLYZATE PRODUCT" to Aharon EYAL
filed on Sep. 27, 2011;
[0014] U.S. 61/552,402 entitled "LIGNIN COMPOSITIONS, METHODS OF
PRODUCING THE COMPOSITIONS, METHODS OF USING LIGNIN, AND PRODUCTS
PRODUCED THEREBY" to Robert JANSEN et al. filed on Oct. 27,
2011;
[0015] U.S. 61/559,529 entitled "LIGNIN COMPOSITIONS, METHODS OF
PRODUCING THE COMPOSITIONS, METHODS OF USING LIGNIN, AND PRODUCTS
PRODUCED THEREBY" to Robert JANSEN et al. filed on Nov. 14, 2011;
and
[0016] U.S. 61/562,931 entitled "Biomass treatment methods" to
Aharon EYAL filed on Nov. 22, 2011; each of which is fully
incorporated herein by reference.
[0017] In addition, this application is related to the following
co-pending patent applications:
[0018] U.S. 61/483,777 entitled "HYDROLYSIS SYSTEMS AND METHODS" to
Robert JANSEN et al. filed on May 9, 2011;
[0019] U.S. 61/487,319 entitled "HYDROLYSIS SYSTEMS AND METHODS" to
Robert JANSEN et al. filed on May 18, 2011;
[0020] U.S. 61/491,243 entitled "LIGNIN COMPOSITIONS, SYSTEMS AND
METHODS FOR PROCESSING LIGNIN AND/OR HCl" to Robert JANSEN et al.
filed on May 30, 2011;
[0021] U.S. 61/500,169 entitled "SUGAR MIXTURES AND METHODS FOR
PRODUCTION AND USE THEREOF" to Aharon EYAL et al. filed on Jun. 23,
2011;
[0022] U.S. 61/501,276 entitled "METHODS OF PROCESSING A SUCROSE
CROP" to Aharon EYAL et al. filed on Jun. 27, 2011;
[0023] U.S. 61/539,272 entitled "METHODS AND SYSTEMS FOR PROCESSING
LIGNOCELLULOSIC MATERIALS" to Robert JANSEN et al. filed on Sep.
26, 2011;
[0024] PCT application US2011/057552 "HYDROLYSIS SYSTEMS AND
METHODS" to JANSEN et al. filed on Oct. 24, 2011; and
[0025] U.S. 61/558,374 entitled "LIGNOCELLULOSE PROCESSING METHODS
AND COMPOSITIONS RESULTING THEREFROM" to Eran BANIEL et al. filed
on Nov. 10, 2011; each of which is fully incorporated herein by
reference.
FIELD OF THE INVENTION
[0026] This invention relates to methods for processing of
lignocellulosic materials including, but not limited to, wood and
to resultant compositions.
BACKGROUND OF THE INVENTION
[0027] The carbohydrate-conversion industry is large. Currently,
about 100 million tons of carbohydrates are fermented annually.
Much of this fermentation produces fuel-grade ethanol.
[0028] Millions of tons of carbohydrates are also fermented every
year to provide food and feed products, such as citric acid and
lysine.
[0029] Fermentation of carbohydrates also produces other products,
such as monomers for the polymer industry, e.g. lactic acid for the
production of polylactide.
[0030] Carbohydrate conversion is an attractive and
environmentally-friendly process since carbohydrates are a
renewable resource. For example sucrose can be produced from sugar
canes and glucose can be produced from corn and wheat starches.
However, sugar cane, corn and wheat are produced primarily for
human consumption and/or as livestock feed. Increased consumption
by industry may impact food costs.
[0031] As an alternative, many renewable non-food resources are
potential sources of carbohydrates. The renewable non-food
resources can generally be described as "woody materials" or
"lignocellulosic materials". These lignocellulosic materials
include, but are not limited to, wood and by-products of wood
processing (e.g. chips, sawdust, and shavings) as well as residual
plant material from agricultural products and paper and paper
industry byproducts (e.g. cellulose containing residues and/or
paper pulp).
[0032] Residual plant material from agricultural products includes
processing by-products and field remains.
[0033] Processing by-products include, but are not limited to, corn
cobs, sugar cane bagasse, sugar beet pulp, empty fruit bunches from
palm oil production, straw (e.g. wheat or rice), soy bean hulls,
residual meals from the vegetable oil industry (e.g. soybean,
peanut, corn or rapeseed), wheat bran and fermentation residue from
the beer and wine industries.
[0034] Field remains include, but are not limited to, corn stover,
post-harvest cotton plants, post-harvest soybean bushes and
post-harvest rapeseed plants.
[0035] Lignocellulosic materials also include "energy crops" such
as switch grass and broom grass which grow rapidly and generate
low-cost biomass specifically as a source of carbohydrates.
[0036] These lignocellulosic carbohydrate sources contain
cellulose, hemicellulose and lignin as their main components can
also contain mineral salts (ashes) and lipophilic organic
compounds, such as tall oils resin acids, fatty acids,
triglycerides and other organic compounds, including volatile
organic compounds such as turpentine. The degree and type of these
non-carbohydrate materials can create technical problems in
production of soluble carbohydrates.
SUMMARY OF THE INVENTION
[0037] A broad aspect of the invention relates to preparation of
lignocellulosic material for additional downstream processing
According to various exemplary embodiments of the invention the
preparation includes removal of water and/or lipophilic impurities
and/or ash which can contribute to ease of function of equipment
used in the downstream processing. Alternatively or additionally,
the preparation includes a thermo-mechanical treatment.
[0038] One aspect of some embodiments of the invention relates to
improvement of a filtration rate of solid lignin from an acid
hydrolyzate. In some embodiments, pretreatment of a lignocellulosic
substrate with a water-soluble organic solvent, optionally
including a weak acid, contributes to the improvement of the
filtration rate. Alternatively or additionally, application of a
predetermined pressure-temperature-time profile to the
lignocellulosic substrate contributes to the improvement of the
filtration rate.
[0039] One aspect of some embodiments of the invention relates to
extraction of a lignocellulosic substrate with a water-soluble
organic solvent, optionally in the presence of a weak acid, to
produce extracted substrate and a liquid extract (miscella).
[0040] For example, a method of the invention comprises (a)
providing a lignocellulosic substrate; (b) contacting said
lignocellulosic substrate with an extractant comprising a
water-soluble organic solvent to form an extracted substrate and a
miscella; and (c) removing miscella from said extracted substrate.
In some instances, the method further includes (d) hydrolyzing said
extracted substrate using a chemically catalyzed process. In some
instances, the method further includes hydrolyzing said extracted
substrate to form a hydrolyzate and lignin solids; and (e)
filtering said lignin solids from said hydrolyzate, wherein a
filtration rate of said filtering is faster by at least 10%
compared with a filtration rate of lignin solids from hydrolyzate
formed by hydrolyzing said substrate without said extracting, using
an identical filter and identical filtration conditions. In some
instances, the method further includes enzymatically hydrolyzing
said extracted substrate. In some instances, the method further
includes subjecting said extracted substrate to a thermal process
involving exposure to temperatures in excess of 200.degree. C. In
some instances, the method further includes subjecting said
extracted substrate to a sulfite treatment process. In some
instances, the method further includes hydrolyzing the extracted
substrate to generate lignin solids and/or carbohydrate and further
processing said lignin solids and/or carbohydrates to make a
consumer product or commercial product.
[0041] One aspect of the invention comprises a method comprising:
removing impurities from a lignocellulosic material and filtering
lignin from said lignocellulosic material, wherein the step of
removing impurities reduces rate of fouling of filter or increases
rate of filtering by at least 20%.
[0042] Another aspect of the invention relates to a miscella
derived from a lignocellulosic biomass subjected to a weak acid and
organic solvent. A miscella or miscella layer as used herein can
comprise a non-carbohydrate materials from lignocellulosic biomass,
a weak acid, and an organic solvent.
[0043] Another aspect of the invention relates to a method for
making a commercial product comprising: removing miscella
comprising impurities from a lignocellulosic biomass; hydrolyzing
said biomass to generate lignin or sugar; and using said lignin or
sugar to make a commercial product.
[0044] Another aspect of some embodiments of the invention relates
to application of a predetermined pressure-temperature-time profile
to a lignocellulosic substrate. As used in this specification and
the accompanying claims the term predetermined
pressure-temperature-time profile includes any thermo-mechanical
treatment. In some exemplary embodiments of the invention,
application of a predetermined pressure-temperature-time profile
can produce a disrupted substrate. Optionally, application of a
predetermined pressure-temperature-time profile can be followed by
extraction with a water-soluble organic solvent. According to
various exemplary embodiments of the invention the predetermined
pressure-temperature-time profile includes steam explosion and/or
expeller treatment (e.g. using a plug screw feeder) and/or ammonia
fiber explosion (AFEX). In some embodiments, the plug screw feeder
treatment includes use of an impressafiner apparatus (Andritz;
Graz, Austria). A description of AFEX is provided by Taherzade and
Karimi (Int. J. Mol. Sci. (2008) 9: 1621-1651) which is fully
incorporated herein by reference.
[0045] Exemplary predetermined pressure-temperature-time profiles
are described in co-pending applications U.S. 61/552,402, U.S.
61/558,374 and U.S. 61/559,529; each of which is fully incorporated
herein by reference.
[0046] In some embodiments of the invention, the
predetermined-pressure-temperature-time profile is applied prior to
contacting the disrupted substrate with extractant.
[0047] In exemplary embodiments in which steam explosion provides
the predetermined-pressure-temperature-time profile, steam from the
steam explosion can optionally be used to evaporate solvent from
the extracted substrate.
[0048] In some embodiments of the invention, the solvent includes
an alcohol and/or ketone with less than 5 carbon atoms. In some
embodiments, the solvent includes acetone or acetone in combination
with water.
[0049] In some embodiments of the invention, production of a
disrupted substrate contributes to an ability of the solvent to
penetrate into the substrate. In some embodiments, increasing
penetration contributes to the efficiency of extraction of one or
more materials in the substrate, and/or an increase in recovery of
the applied solvent.
[0050] An additional aspect of some embodiments of the invention
relates to removal of at least 50% of the ash from the
lignocellulosic substrate. In some exemplary embodiments of the
invention, the removed portion of the ash includes at least 40%,
50%, or 60% of the magnesium (Mg) and calcium (Ca) originally
present in the substrate. Optionally, removal of ash in general
and/or Ca and/or Mg contributes to a reduction in complications of
downstream processing of the extracted substrate.
[0051] An additional aspect of some embodiments of the invention
relates to removal of at least 50% of total lipophilic materials
from the lignocellulosic substrate. Optionally, removal of
lipophilic materials contributes to a reduction in complications of
downstream processing of the extracted substrate.
[0052] According to exemplary embodiments of the invention, the
downstream processing includes hydrolysis in the presence of a
reactive fluid, such as a supercritical fluid, and/or hydrolysis in
the presence of a mineral acid such as HCl and/or H.sub.2SO.sub.4
and/or pyrolysis and/or gasification.
[0053] An additional aspect of some embodiments of the invention
relates to extraction with a water-soluble organic solvent, in the
presence of a weak acid, to produce extracted substrate and
miscella, removing the miscella, and subjecting the extracted
substrate to hydrolysis and/or pyrolysis and/or gasification.
[0054] In some exemplary embodiments, hydrolysis is conducted in
the presence of HCl and/or H.sub.2SO.sub.4 and/or a reactive
fluid.
[0055] In some exemplary embodiments of the invention, the
extraction is conducted at a temperature of less than about
60.degree. C.
[0056] In some exemplary embodiments of the invention, the solvent
includes an alcohol and/or ketone and/or aldehyde and/or ester with
less than 5 carbon atoms. In some embodiments, the solvent includes
acetone.
[0057] In some exemplary embodiments of the invention, the weak
acid has a boiling point of 120.degree. C. or less at atmospheric
pressure.
[0058] In some exemplary embodiments, the weak acid includes
sulfurous acid and/or acetic acid.
[0059] Alternatively or additionally, at least one of the weak acid
and the solvent does not form an azeotrope with water.
[0060] Optionally, these characteristics of the acid and/or solvent
contribute to an ease of removal of residual extractant from the
extracted substrate.
[0061] In some exemplary embodiments, the weak acid hydrolyzes less
than 10% of the cellulose in the substrate during the extraction
process.
[0062] In some exemplary embodiments, the weak acid hydrolyzes less
than 10% of the hemicellulose in the substrate during the
extraction process.
[0063] In some exemplary embodiments, the method of the present
invention includes two or more extraction stages, each of which may
be characterized by a ratio between the weak acid and the solvent
which is independent of the ratio of acid to solvent in the other
extraction stages.
[0064] In some exemplary embodiments, the method of the present
invention includes multi-stage counter-current contacting between
the substrate and the extractant.
[0065] In some exemplary embodiments, the method of the present
invention comprises performing an additional extraction with a
second extractant including a water-soluble organic solvent.
[0066] In some exemplary embodiments, the extractant comprises a
water-soluble organic solvent and an alkali.
[0067] In some exemplary embodiments, the miscella is removed by
draining and/or active removal.
[0068] In some exemplary embodiments, the lignocellulosic substrate
is wood.
[0069] In some exemplary embodiments, the lignocellulosic substrate
is harvested at least 5 days before extracting.
[0070] Another additional aspect of some embodiments of the
invention relates to fractionation of the miscella, optionally by
step-wise removal of solvent, to recover extracted materials.
[0071] According to various exemplary embodiments of the invention
the extracted materials include one or more lipophilic components,
such as oils, resins and resinic acids. In some embodiments, the
fractionation is based upon a degree of hydrophobicity. In some
exemplary embodiments of the invention, the extracted components
have an economic value of their own which can be used to at least
partially offset process costs. Alternatively or additionally,
fractionation of the miscella to recover extracted materials
contributes to recovery and/or re-use of the solvent and/or the
weak acid as described in the previous aspect.
[0072] In some exemplary embodiments, the solvent and/or the weak
acid are recovered from the miscella. Optionally, this recovery
contributes to a reduction in process costs.
[0073] In some exemplary embodiments of the invention, recovery
includes separating the solvent and/or weak acid from miscella. In
some exemplary embodiments, separation includes distilling the
miscella to form a solvent phase, an aqueous phase and a lipophilic
fraction.
[0074] In some embodiments, the solvent phase includes the solvent
and a portion of weak acid.
[0075] In some exemplary embodiments, separation includes
fractionation of the lipophilic phase.
[0076] In some exemplary embodiments, the aqueous phase is
subjected to anaerobic treatment to produce methane.
[0077] Yet another additional aspect of some embodiments of the
invention relates to use of water-soluble hydrocarbons from the
miscella. In some exemplary embodiments of the invention, these
water-soluble hydrocarbons are used to produce methane. Optionally,
the methane is produced in an anaerobic digester.
[0078] Yet another additional aspect of some embodiments of the
invention relates to a system for processing lignocellulosic
material which includes an extraction module adapted to extract the
lignocellulosic material prior to hydrolysis in a hydrolysis
module.
[0079] In some embodiments, the system includes a dryer for
removing residual extractant. In some exemplary embodiments of the
invention, the hydrolysis module employs a concentrated acid
stream, for example, a concentrated HCl stream.
[0080] According to various exemplary embodiments of the invention
the concentrated HCl stream includes 35%, 37%, 40%, 42% or 43% HCl
or intermediate or greater percentages expressed as
(HCl/(HCl+water)).
[0081] An additional aspect of some embodiments of the invention
relates to a system comprising a distillation column for separating
impurities from the miscella and recycling said miscella on the one
hand and for forming a lipophilic fraction stream and a
hydrocarbon-containing aqueous phase on the other hand.
[0082] Various exemplary embodiments of the invention relate to
methods for processing an extracted substrate as described above to
produce a sugar mixture. In some embodiments, the sugar mixture can
then be converted to a conversion product using one or more
additional processes.
[0083] Various exemplary embodiments of the invention relate to
methods for converting at least a portion of an extracted substrate
as described above to a conversion product. Optionally, conversion
does not involve an intermediate sugar stage.
[0084] An additional aspect of some embodiments of the invention
relates to extracted pine wood. In some exemplary embodiments of
the invention, the extracted wood comprises at least 35% cellulose;
at least 7.4% hemicellulose; and less than 0.7% ash, on a dry
weight basis. Optimally, the extracted wood comprises less than 2%
dichloromethane (DCM) extractives. Alternatively or additionally,
the extracted wood optionally comprises less than 50%, less than
30%, less than 20% or less than 10% of the moisture content of the
pine wood on an absolute basis prior to extraction. In some
embodiments, at least 10% of the cells in the extracted wood are
disrupted. In some embodiments, the extracted wood includes
acetone.
[0085] In some embodiments, wood includes about 50% water. In some
embodiments, the substrate includes about 60% water after a thermo
mechanical treatment. Alternatively or additionally, the same
substrate includes about 13-16% water after extraction.
[0086] An additional aspect of some embodiments of the invention
relates to an extraction mixture. In some exemplary embodiments of
the invention, the mixture comprises one part lignocellulosic
substrate and at least 2 parts acetone, on a weight basis.
Optionally, the extraction mixture includes less than 3 parts
acetone.
[0087] According to various exemplary embodiments of the invention,
the extraction mixture includes a weak acid, for example acetic
acid and/or sulfurous acid. Optionally, the extraction mixture
includes added water.
[0088] Exemplary downstream uses include, but are not limited to;
acid hydrolysis to produce soluble sugars and/or lignin and
production of paper from the lignocellulosic material.
[0089] In some exemplary embodiments of the invention, there is
provided a lignocellulosic composition including (on a dry matter
basis) cellulose, hemicellulose, lignin and characterized by at
least one characteristic selected from the group consisting of:
[0090] less than 5,000 PPM, optionally less than 3,000 PPM,
optionally less than 2,000 PPM, optionally less than 1,000 PPM,
optionally less than 500 PPM lipophilic material; [0091] less than
5,000 PPM, optionally less than 3,000 PPM, optionally less than
2,000 PPM, optionally less than 1,000 PPM, optionally less than 500
PPM ash; [0092] less than 2,000 PPM, optionally less than 1,500
PPM, optionally less than 1,000 PPM, optionally less than 500 PPM
Ca; [0093] less than 10,000 PPM, optionally less than 8,000 PPM,
optionally less than 6,000 PPM, optionally less than 4,000 PPM,
optionally less than 2,000 PPM, optionally less than 1,000 pectin;
[0094] less than 2,000 PPM, optionally less than 1,500 PPM,
optionally less than 1,000 PPM, optionally less than 500 PPM
furfural; [0095] at least 10 PPM of a marker selected from the
group consisting of furfural, organically bound sulfur and water
soluble solvent (e.g. acetone); and [0096] a moisture content of 5%
to 30%, optionally 8% to 25%, optionally 10% to 20%.
[0097] In some embodiments, the composition is characterized by at
least two, optionally at least three, optionally at least four,
optionally at least 5 characteristics selected from the above
group.
[0098] In some exemplary embodiments of the invention, there is
provided a method including:
[0099] (a) providing a lignocellulosic substrate; (b) contacting
the lignocellulosic substrate with an extractant comprising a
water-soluble organic solvent to form an extracted substrate and a
miscella; (c) removing miscella from the extracted substrate (d)
hydrolyzing the extracted substrate to form a hydrolyzate and
lignin solids; and (e) filtering the lignin solids from the
hydrolyzate; wherein a filtration rate of the filtering is faster
by at least 10% compared with a filtration rate of lignin solids
from hydrolyzate formed by hydrolyzing the substrate without the
extracting, using an identical filter and identical filtration
conditions.
[0100] In some exemplary embodiments of the invention, there is
provided a method including:
[0101] (a) providing a lignocellulosic substrate; (b) contacting
the lignocellulosic substrate with an extractant comprising a
water-soluble organic solvent to form an extracted substrate and a
miscella;
[0102] (c) removing miscella from the extracted substrate; and (d)
hydrolyzing the extracted substrate using a chemically catalyzed
process.
[0103] In some embodiments, the hydrolyzing employs a mineral acid
as a catalyst.
[0104] In some embodiments, the mineral acid includes HCl.
[0105] In some embodiments, the mineral acid includes
H.sub.2SO.sub.4.
[0106] In some embodiments, the hydrolyzing employs reactive fluid
as a catalyst.
[0107] In some exemplary embodiments of the invention, there is
provided a method including: (a) providing a lignocellulosic
substrate; (b) contacting the lignocellulosic substrate with an
extractant comprising a water-soluble organic solvent to form an
extracted substrate and a miscella; (c) removing miscella from the
extracted substrate; and (d) enzymatically hydrolyzing the
extracted substrate.
[0108] In some embodiments, the method includes subjecting the
extracted substrate to a sulfite process.
[0109] In some exemplary embodiments of the invention, there is
provided a method including: (a) providing a lignocellulosic
substrate; (b) contacting the lignocellulosic substrate with an
extractant comprising a water-soluble organic solvent to form an
extracted substrate and a miscella; (c) removing miscella from the
extracted substrate; and (d) subjecting the extracted substrate to
a thermal process involving exposure to temperatures in excess of
200.degree. C.
[0110] In some embodiments, the thermal process includes
pyrolysis.
[0111] In some embodiments, the thermal process includes
gasification.
[0112] In some exemplary embodiments of the invention, there is
provided a method including: (a) providing a lignocellulosic
substrate; (b) contacting the lignocellulosic substrate with an
extractant comprising a water-soluble organic solvent to form an
extracted substrate and a miscella; (c) removing miscella from the
extracted substrate; and (d) subjecting the extracted substrate to
a sulfite process.
[0113] In some exemplary embodiments of the invention, there is
provided a substrate processing method, the method including: (a)
contacting a lignocellulosic substrate with a first extractant
including a water-soluble organic solvent and a weak acid to form
an extracted substrate and a miscella; (b) removing at least a
portion of the miscella from the extracted substrate; and (c)
hydrolyzing the extracted substrate with a strong acid to produce a
hydrolyzate containing soluble sugars.
[0114] In some exemplary embodiments of the invention, there is
provided a method comprising applying a predetermined
pressure-temperature-time profile to a lignocellulosic substrate
(b) contacting the substrate with an extractant comprising a
water-soluble organic solvent and a weak acid to form an extracted
substrate and a miscella; and (c) processing the extracted
substrate.
[0115] In some embodiments, applying the predetermined
pressure-temperature-time profile disrupts the substrate.
[0116] In some exemplary embodiments of the invention, there is
provided a method including:
[0117] (a) providing a lignocellulosic substrate;
[0118] (b) contacting said lignocellulosic substrate with an
extractant comprising a water-soluble organic solvent to form an
extracted substrate;
[0119] (c) hydrolyzing said extracted substrate to form a
hydrolyzate and a lignin solids; and
[0120] (d) filtering said lignin solids from said hydrolyzate,
[0121] wherein a filtration rate of said filtering is faster by at
least 10% compared with a filtration rate of lignin solids from
hydrolyzate formed by hydrolyzing said substrate without said
extracting, using an identical filter and identical filtration
conditions.
[0122] Optionally, the extracting forms a miscella, and the method
includes removing at least a portion of the miscella from the
extracted substrate.
[0123] Optionally, the water-soluble organic solvent includes at
least one solvent selected from the group consisting of ketones,
aldehydes, esters and alcohols with up to four carbon atoms.
[0124] Optionally, the water-soluble organic solvent includes
acetone.
[0125] Optionally, the methods include applying of a
predetermined-pressure-temperature-time profile prior to contacting
the substrate with the extractant.
[0126] In some exemplary embodiments, processing of the extracted
substrate includes hydrolysis in the presence of a reactive fluid
to produce soluble sugars.
[0127] In some exemplary embodiments, processing of the extracted
substrate includes hydrolysis in the presence of a mineral acid to
produce soluble sugars. Optionally, the mineral acid comprises at
least one of hydrochloric acid and sulfuric acid.
[0128] In some exemplary embodiments, processing of the extracted
substrate includes enzymatic hydrolysis to produce soluble
sugars.
[0129] In some exemplary embodiments, processing of the extracted
substrate includes pyrolysis.
[0130] In some exemplary embodiments, processing of the extracted
disrupted substrate includes gasification.
[0131] In some exemplary embodiments, the predetermined
pressure-temperature-time profile comprises a steam explosion
treatment. Optionally, the steam explosion treatment comprises
application of steam at a desired pressure and temperature for a
time period in the range of from about 10 seconds to about 5
minutes, optionally from about 30 seconds to about 3 minutes. In
some exemplary embodiments of the invention, the desired pressure
can be in the range of from about 6 atm to about 45 atm.
Application of steam under pressure is followed by rapid venting of
pressure. Optionally, steam is applied at a temperature in the
range of from about 170.degree. C. to about 230.degree. C.,
optionally about 190.degree. C. to about 210.degree. C. Optionally,
steam from the steam explosion treatment is used to evaporate
solvent from the extracted substrate.
[0132] In some exemplary embodiments, extracting is conducted at a
temperature of less than 70.degree. C., optionally less than
60.degree. C.
[0133] In some exemplary embodiments, extracting is conducted at an
ambient pressure.
[0134] In some exemplary embodiments, the predetermined
pressure-temperature-time profile comprises an ammonia explosion
treatment.
[0135] In some exemplary embodiments, the predetermined
pressure-temperature-time profile comprises treatment with a plug
screw feeder.
[0136] Optionally, the extractant includes a weak acid.
[0137] Optionally, the weak acid is selected from the group
consisting of sulfurous acid and acetic acid.
[0138] Optionally, the weak acid in the extractant hydrolyzes less
than 10% of cellulose in the substrate during said extracting until
said removing.
[0139] Optionally, the weak acid in said extractant hydrolyzes less
than 10% of hemicellulose in the substrate during the extracting
and until the removing.
[0140] Optionally, the extracting is conducted at a temperature of
less than 70.degree. C.
[0141] Optionally, the extracting is conducted at an ambient
pressure.
[0142] Optionally, the extracted substrate contains less than 50%;
optionally less than 40%; optionally less than 35%; optionally less
than 25% of the water provided in said lignocellulosic
substrate.
[0143] Optionally, the extracted substrate contains less than 50%
of the ash content provided in said lignocellulosic substrate.
[0144] Optionally, the extracted substrate contains less than 50%
of the Mg+Ca content provided in said lignocellulosic
substrate.
[0145] Optionally, the extracted substrate contains less than 50%
of the lipophilic materials provided in said lignocellulosic
substrate.
[0146] In some exemplary embodiments of the invention, there is
provided a method comprising contacting a lignocellulosic substrate
with an extractant comprising a water-soluble organic solvent to
form an extracted substrate and a miscella; (b) removing miscella
from the extracted substrate; and (c) hydrolyzing the extracted
substrate using a mineral acid as a catalyst.
[0147] Optionally, the mineral acid comprises hydrochloric
acid.
[0148] Optionally, the mineral acid comprises sulfuric acid.
[0149] In some exemplary embodiments of the invention, there is
provided a method comprising (a) contacting a lignocellulosic
substrate with an extractant comprising a water-soluble organic
solvent to form an extracted substrate and a miscella; (b) removing
miscella from the extracted substrate; and (c) pyrolyzing the
extracted substrate.
[0150] In some exemplary embodiments of the invention, there is
provided a method comprising (a) contacting a lignocellulosic
substrate with an extractant comprising a water-soluble organic
solvent to form an extracted substrate and a miscella; (b) removing
miscella from the extracted substrate; and (c) gasifying the
extracted substrate.
[0151] In some exemplary embodiments of the invention, there is
provided a method comprising; (a) contacting a lignocellulosic
substrate with an extractant comprising a water-soluble organic
solvent to form an extracted substrate and a miscella; (b) removing
miscella from the extracted substrate; and (c) hydrolyzing the
extracted substrate in the presence of a reactive fluid.
[0152] In some exemplary embodiments, subsequent to removal of the
miscella from the extracted substrate, the substrate is subjected
to a sulfite process.
[0153] Optionally, the extractant comprises a weak acid.
[0154] Optionally, the method comprises applying a predetermined
pressure-temperature-time profile to said lignocellulosic
substrate. In some embodiments, applying a predetermined
pressure-temperature-time profile disrupts cellular structures in
the substrate. Optionally, removing of miseclla includes
draining
[0155] Optionally, removing includes active removal.
[0156] Optionally, the method includes harvesting a lignocellulosic
substrate and allowing at least 5 days between harvesting and
contacting.
[0157] Optionally, the lignocellulosic substrate is wood.
[0158] Optionally, less than 10% of cellulose in said
lignocellulosic substrate hydrolyzes before said removing.
[0159] Optionally, less than 10% of hemicellulose in said
lignocellulosic substrate hydrolyzes before said removing.
[0160] Optionally, the water-soluble organic solvent includes at
least one solvent selected from the group consisting of ketones,
aldehydes, esters and alcohols with up to four carbon atoms.
[0161] Optionally, the water-soluble organic solvent includes
acetone.
[0162] Optionally, the extractant comprises a weak acid.
[0163] Optionally, the weak acid includes at least one acid
selected from the group consisting of sulfurous acid and acetic
acid. Optionally, the weak acid has a boiling point lower than
120.degree. C. at atmospheric pressure.
[0164] Optionally, at least one of the weak acid and the solvent
does not form an azeotrope with water.
[0165] Optionally, the contacting includes two or more extraction
stages and each of the two or more extraction stages is
characterized by a ratio between the weak acid and the solvent in
the extractant independent of a same ratio in one or more other
extraction stages of the two or more extraction stages.
[0166] Optionally, the extraction includes multi-stage
counter-current contacting between the substrate and the
extractant.
[0167] Optionally, the first extractant includes water, wherein the
extraction includes two or more extraction stages and wherein each
of the two or more extraction stages is characterized by a ratio
between the water and the solvent in the extractant independent of
a same ratio in one or more other extraction stages of the two or
more extraction stages.
[0168] Optionally, a ratio between the water-soluble organic
solvent in the first extractant and water in the substrate is at
least 2.0 on a weight basis.
[0169] Optionally, the method includes separating at least a
portion of at least one of the water-soluble organic solvent and
the weak acid from the miscella.
[0170] Optionally, the method includes distilling the miscella to
produce a solvent phase, an aqueous phase and a lipophilic
fraction. Optionally, steam generated by the predetermined
pressure-temperature-time profile is applied to the lipophilic
fraction to recover solvent therefrom.
[0171] Optionally, the solvent phase includes the water-soluble
organic solvent and at least a portion of the weak acid.
[0172] Optionally, the method includes fractionation of the
lipophilic fraction of the miscella.
[0173] Optionally, the method includes using steam generated by
said predetermined pressure-temperature-time profile to evaporate
said solvent from said miscella.
[0174] Optionally, the method includes anaerobic treatment of the
aqueous phase to produce methane.
[0175] Optionally, the extracted substrate contains less than 50%;
optionally less than 40%; optionally less than 30%; optionally less
than 25%, optionally less than 20%, optionally less than 18% of the
water provided in the lignocellulosic substrate.
[0176] Optionally, the extracted substrate contains less than 50%
of the ash content provided in the lignocellulosic substrate.
[0177] Optionally, the extracted substrate contains less than 50%
of the Mg+Ca content provided in the lignocellulosic substrate.
[0178] Optionally, the extracted substrate contains less than 50%
of the lipophilic materials originally provided in the
lignocellulosic substrate.
[0179] Optionally, the method includes performing an additional
extraction with a second extractant including the water-soluble
organic solvent.
[0180] Optionally, the hydrolyzing includes acid hydrolysis in an
aqueous medium including at least 35%; HCl:(HCl+water)W/W.
[0181] Optionally, the method includes an alkaline treatment of at
least one of the substrate and the extracted substrate to form a
lipophilic fraction depleted substrate and a solution including an
alkali salt of fatty acid.
[0182] Optionally, the extractant includes the water-soluble
organic solvent and an alkali.
[0183] Optionally, the method includes separating miscella from the
extracted substrate.
[0184] Optionally, the predetermined pressure-temperature-time
profile comprises a steam explosion treatment.
[0185] Optionally, the predetermined pressure-temperature-time
profile includes application of a pressure in the range of from
about 6 atm to about 45 atm for a time period in the range of from
about 10 seconds to about 5 minutes, optionally from about 30
seconds to about 3 minutes (measure time at the target
pressure/temperature).
[0186] Optionally, the contacting is conducted at a temperature of
less than 60.degree. C.
[0187] Optionally, the predetermined pressure-temperature-time
profile comprises an ammonia explosion treatment.
[0188] Optionally, the predetermined pressure-temperature-time
profile comprises treatment with a plug screw feeder.
[0189] Optionally, the weak acid is selected from the group
consisting of sulfurous acid and acetic acid.
[0190] In some exemplary embodiments of the invention, there is
provided a method including: (a) contacting a lignocellulosic
substrate with an extractant comprising a water-soluble organic
solvent to form an extracted substrate and a miscella; (b) removing
miscella from the extracted substrate; (c) subjecting the extracted
substrate to a sulfite process; and (d) enzymatically hydrolyzing
the extracted substrate.
[0191] In some exemplary embodiments of the invention, there is
provided a method including:
[0192] (a) providing a hydrolyzate containing soluble sugars as
described above; and (b) converting at least a portion of the
sugars to a conversion product.
[0193] In some exemplary embodiments of the invention, there is
provided a method including: (a) providing an extracted substrate
as described above; and (b) converting at least a portion of said
substrate to a conversion product.
[0194] Optionally, the converting of the sugars includes a process
selected from the group consisting of fermentation, chemical
conversion, enzymatic conversion, electrolytic reduction, catalytic
hydrogenation, and isomerization.
[0195] Optionally, the converting of the extracted substrate
includes a process selected from the group consisting of pyrolysis,
gasification, aqueous phase re-forming, hydrolysis, hydrogenolysis,
chemical conversion, enzymatic conversion, electrolytic reduction,
catalytic hydrogenation, and isomerization.
[0196] Optionally, the fermentation includes anaerobic
fermentation.
[0197] Optionally, the conversion product includes at least one
member selected from the group consisting of alcohols, carboxylic
acids, amino acids, monomers for the polymer industry, yeast,
methane and proteins.
[0198] Optionally, the method includes processing the conversion
product to produce a consumer product selected from the group
consisting of detergent, polyethylene-based products,
polypropylene-based products, polyolefin-based products, polylactic
acid (polylactide)-based products, polyhydroxyalkanoate-based
products and polyacrylic-based products.
[0199] Optionally, the detergent includes a sugar-based surfactant,
a fatty acid-based surfactant, a fatty alcohol-based surfactant, or
a cell-culture derived enzyme.
[0200] Optionally, the polyacrylic-based product is selected from
plastics, floor polishes, carpets, paints, coatings, adhesives,
dispersions, flocculants, elastomers, acrylic glass, absorbent
articles, incontinence pads, sanitary napkins, feminine hygiene
products, and diapers.
[0201] Optionally, the polyolefin-based products are selected from
milk jugs, detergent bottles, margarine tubs, garbage containers,
water pipes, absorbent articles, diapers, non wovens, HDPE toys and
HDPE detergent packaging.
[0202] Optionally, the polypropylene based products are selected
from absorbent articles, diapers and non wovens.
[0203] Optionally, the polylactic acid based products are selected
from packaging of agriculture products and of dairy products,
plastic bottles, biodegradable products and disposables.
[0204] Optionally, the polyhydroxyalkanoate based products are
selected from packaging of agriculture products, plastic bottles,
coated papers, molded or extruded articles, feminine hygiene
products, tampon applicators, absorbent articles, disposable
nonwovens and wipes, medical surgical garments, adhesives,
elastomers, films, coatings, aqueous dispersants, fibers,
intermediates of pharmaceuticals and binders.
[0205] Optionally, the conversion product includes at least one
member of the group consisting of methane, ethanol, butanol,
isobutanol, a fatty acid, a fatty acid ester, a fatty alcohol and
biodiesel.
[0206] Optionally, the method includes processing of the conversion
product to produce at least one product selected from the group
consisting of an isobutene condensation product, jet fuel,
gasoline, gasohol, diesel fuel, drop-in fuel, diesel fuel additive,
and a precursor thereof.
[0207] Optionally, the gasahol is ethanol-enriched gasoline or
butanol-enriched gasoline.
[0208] Optionally, the product is selected from the group
consisting of diesel fuel, gasoline, jet fuel and drop-in
fuels.
[0209] In some exemplary embodiments of the invention, there is
provided a consumer product, a precursor of a consumer product, or
an ingredient of a consumer product produced from a conversion
product as described above.
[0210] Optionally, the consumer product, precursor of a consumer
product, or ingredient of a consumer product includes at least one
conversion product produced by a method described above,
[0211] wherein the fermentation product is selected from carboxylic
and fatty acids, dicarboxylic acids, hydroxylcarboxylic acids,
hydroxyl di-carboxylic acids, hydroxyl-fatty acids, methylglyoxal,
mono-, di-, or poly-alcohols, alkanes, alkenes, aromatics,
aldehydes, ketones, esters, biopolymers, proteins, peptides, amino
acids, vitamins, antibiotics, and pharmaceuticals.
[0212] Optionally, the product is ethanol-enriched gasoline, jet
fuel, or biodiesel.
[0213] Optionally, the consumer product, precursor of a consumer
product, or ingredient of a consumer product has a ratio of
carbon-14 to carbon-12 of about 2.0.times.10.sup.-13 or
greater.
[0214] In some exemplary embodiments of the invention, the consumer
product includes an ingredient as described above and an additional
ingredient produced from a raw material other than lignocellulosic
material.
[0215] Optionally, the ingredient and the additional ingredient
produced from a raw material other than lignocellulosic material
are essentially of the same chemical composition.
[0216] Optionally, the consumer product includes a marker molecule
at a concentration of at least 100 ppb.
[0217] Optionally, the marker molecule is selected from the group
consisting of furfural, hydroxy-methyl furfural, products of
furfural or hydroxy-methylfurfural condensation, color compounds
derived from sugar caramelization, levulinic acid, acetic acid,
methanol, galacturonic acid, and glycerol.
[0218] In some exemplary embodiments of the invention, there is
provided a system including:
[0219] (a) an extraction module adapted to extract a
lignocellulosic substrate with an extractant including a
water-soluble organic solvent and a weak acid, and to output an
extracted substrate and an impurity rich extract; (b) a hydrolysis
module adapted to receive the extracted substrate and to contact it
with hydrochloric acid at a concentration of at least 30% to
produce an acid hydrolyzate.
[0220] Optionally, the extraction module delivers an extractant
formulated to extract at least 30%; optionally at least 40%;
optionally 50% or more of ash present in said substrate.
[0221] Optionally, the system includes a dryer adapted to remove
extractant from the extracted substrate;
[0222] Optionally, the system includes a disruption module adapted
to apply a predetermined pressure-temperature-time profile to the
substrate.
[0223] Optionally, the disruption module includes at least one item
selected from the group consisting of a plug screw feeder and an
explosion reactor (e.g. steam explosion or ammonia explosion).
[0224] Optionally, the system includes a distillation column
adapted to obtain the impurity rich extract and return at least a
portion of the solvent to the extraction module.
[0225] Optionally, the system includes a methane generator adapted
to obtain the hydrocarbon including an aqueous phase.
[0226] In some exemplary embodiments of the invention, there is
provided an extracted lignocellulose composition including (on a
dry weight basis): (a) at least 35% cellulose; (b) at least 7.4%
hemicellulose; and (c) less than 0.7% ash.
[0227] Optionally, the composition includes less than 2% DCM
(dichloromethane) extractives.
[0228] Optionally, the composition includes less than 50% of the
moisture content of the pine wood prior to extraction.
[0229] Optionally, at least 10% of the cells are disrupted.
[0230] Optionally, the composition includes acetone.
[0231] Optionally, the lignocellulose includes pine wood.
[0232] Optionally, the composition includes at least 0.01%,
optionally 0.005% by weight, of an acid selected from the group
consisting of sulfurous acid, acetic acid and carbonic acid.
[0233] In some exemplary embodiments of the invention, there is
provided an extraction mixture including (on a weight basis): (a)
one part lignocellulosic substrate; and (b) at least 2 parts
acetone.
[0234] Optionally, the mixture includes less than 3 parts
acetone.
[0235] Optionally, the mixture includes a weak acid.
[0236] Optionally, the weak acid includes at least one of acetic
acid, sulfurous acid and carbonic acid.
[0237] Optionally, the mixture includes added water.
[0238] In some embodiments, there is provided a method for
processing a lignocellulosic material into a hydrolyzate product, a
primary lignin product and optionally a secondary lignin product,
comprising: (a) providing a lignocellulosic feed material
comprising at least one insoluble polysaccharide and lignin; (b)
hydrolyzing a fraction of said insoluble polysaccharide in an
HCl-comprising hydrolysis medium to form a hydrolyzate, which
hydrolyzate comprises at least one carbohydrate and HCl, and a
lignin stream comprising solid lignin, HCl and water, (c)
separating said hydrolyzate from said lignin stream to form a
separated hydrolyzate and a separated lignin stream, (d)
de-acidifying said separated hydrolyzate to form a de-acidified,
carbohydrate-comprising hydrolyzate; (e) processing said
de-acidified carbohydrate-comprising hydrolyzate into at least one
hydrolyzate product; (f) de-acidifying said separated lignin stream
to form de-acidified lignin; (g) treating said de-acidified lignin
at an elevated temperature, in an oxygen-deficient atmosphere to
form at least one primary lignin product and optionally converting
said primary lignin product to form at least one secondary lignin
product and excess heat, (h) optionally treating at least one of
said hydrolyzate product, said primary lignin product, and said
secondary lignin product and (i) using said excess heat in at least
one of steps (a) to (f) and (h).
[0239] According to various exemplary embodiments of the invention
any lignocellulosic material is used in the method. For example,
the material can include one or more of wood, sugarcane bagass,
palm oil biomass, other agriculture residues and energy crops.
[0240] The provided lignocellulosic material comprises at least one
insoluble polysaccharide. As used herein, the term insoluble means
water-insoluble. According to an embodiment, the insoluble
polysaccharide is selected from the group consisting of
hemicellulose, amorphous cellulose and crystalline cellulose. In
some embodimentsthe lignocellulosic feed material comprises two or
three of those polysaccharides.
[0241] Hydrolyzing a fraction of said insoluble polysaccharide in
an HCl-comprising hydrolysis medium comprises contacting said
lignocellulosic feed material with a hydrolysis medium. Exemplary
forms of contacting are described in, for example, co-pending
application PCT/US11/57552; which is fully incorporated herein by
reference.
[0242] In some embodiments, in said HCl-comprising hydrolysis
medium the weight ratio between HCl and (HCl+water) is in the range
between 0.25 and 0.50, between 0.30 and 0.45 or between 0.35 and
0.40.
[0243] In some embodiments, the ratio between the weight of soluble
carbohydrates in the hydrolyzate and the weight of the soluble
carbohydrates combined with the weight of water is between 0.15 and
0.40.
[0244] The hydrolysis also forms a lignin stream comprising solid
lignin, HCl and water. In some embodiments, the solid lignin
constitutes the majority of the lignin stream, while according to
another embodiment, solid lignin is dispersed in the lignin stream.
Typically the solid lignin is swelled with an HCl aqueous solution.
The lignin stream may contain, according to various embodiments,
additional compounds, such as carbohydrates and polysaccharides. In
some embodiments, the lignin stream comprises solid lignin as well
as an insoluble polysaccharide. Optionally, the insoluble
polysaccharide is a residual polysaccharide from the insoluble
polysaccharide in the lignocellulosic material. According to an
embodiment, said residual insoluble polysaccharides correspond to
at least 5% of the insoluble polysaccharide in the lignocellulosic
material. According to an embodiment, at least 50%, at least 70% or
even at least 90% of the residual insoluble polysaccharide is
crystalline.
[0245] In some exemplary embodiments of the invention, the method
includes separating the hydrolyzate from the lignin stream to form
separated hydrolyzate and separated lignin stream, de-acidifying
the separated hydrolyzate and de-acidifying the separated lignin
stream. Any form of separation and of deacidification is suitable.
In some embodiments, de-acidifying of the hydrolyzate,
de-acidifying of the lignin stream or both comprise contacting with
an organic solvent.
[0246] Optionally, the organic solvent is selected from the group
consisting of aliphatic or aromatic alcohols, ketones and aldehydes
having at least 5 carbon atoms, e.g. various pentanols, hexanols,
heptanols, octanols, nonanols, decanols, methyl-isobutyl-ketone and
methyl-butyl-ketone and combinations thereof. As used here, the
term alcohols means any of mono-, di- and poly-alcohols, primary,
secondary and tertiary ones, straight-chain and branched-chain
alcohols and any combination thereof. According to a preferred
embodiment, the solvent is selected from hexanol and
2-ethyl-1-hexanol and a mixture thereof.
[0247] Alternatively or additionally, de-acidifying of the
hydrolyzate includes chromatographic separation.
[0248] Additional details of exemplary methods to de-acidify the
hydrolyzate can be found in co-pending applications IL 211093 and
U.S. 61/524,839; PCT/IL2011/000424 and PCT/IL2011/000304; the
teachings of which are incorporated herein by reference.
[0249] De-acidifying the hydrolyzate forms a de-acidified,
carbohydrate-containing hydrolyzate. According to an embodiment,
said de-acidified, carbohydrate-containing hydrolyzate is
characterized by a hydrochloric acid to carbohydrates weight ratio
of less than 0.01, less than 0.005 or even less than 0.002.
[0250] In some exemplary embodiments of the invention, the method
includes processing the de-acidified carbohydrate-containing
hydrolyzate into at least one hydrolyzate product. According to
various exemplary embodiments of the invention this processing
includes at least one of polishing, oligomer hydrolysis, chemically
catalyzed conversion and biocatalyzed conversion. Optionally, the
processing includes fermenting carbohydrates in said de-acidified
carbohydrate-containing hydrolyzate. According to various exemplary
embodiments of the invention the hydrolyzate product is selected
from the group consisting of ethanol, butanol, other alcohols,
amino acids, carboxylic acids and monomers for the polymer
industry.
[0251] Alternatively or additionally, in some embodiments,
de-acidifying the lignin stream is conducted as described in
co-pending application PCT/IL2011/000424 and PCT/IL2011/000304;
each of which is fully incorporated herein by reference.
[0252] De-acidifying the lignin stream forms de-acidified lignin.
Optionally, the de-acidified lignin is characterized by a
hydrochloric acid to carbohydrates weight ratio of less than 0.01,
less than 0.005 or even less than 0.002.
[0253] According to various exemplary embodiments of the invention
forming of de-acidified lignin includes at least one of separation
of solid lignin from an aqueous medium, separation of solid lignin
from a solvent medium and drying of solid lignin. In some
embodiments, the de-acidified lignin is a solid composition
including mainly lignin. Optionally, the solid includes residual
polysaccharide.
[0254] In some exemplary embodiments of the invention, the method
includes treating the de-acidified lignin at an elevated
temperature, in an oxygen-deficient atmosphere to form at least one
primary lignin product. Optionally, the method includes converting
the primary lignin product to form at least one secondary lignin
product and excess heat. In some embodiments, the treating includes
at least one of pyrolysis and gasification. Alternatively or
additionally, the primary lignin product is selected from the group
consisting of biocrude, hydrogen, carbon mono-oxide and carbon
dioxide.
[0255] In some embodiments, the method includes converting the
primary lignin product into a secondary lignin product. As used in
this specification and the accompanying claims the term "secondary
lignin product" indicates a product formed by converting a primary
lignin product. According to various exemplary embodiments of the
invention this converting includes at least one of chemically
catalyzed conversion and biocatalyzed conversion. In some
embodiments, biocatalyzed conversion includes fermentation of the
primary lignin product.
[0256] According to various exemplary embodiments of the invention
the secondary lignin product is selected from the group consisting
of ethanol, butanol, other alcohols, amino acids, carboxylic acids
and monomers for the polymer industry.
[0257] In some embodiments, the carbon contents of the
lignocellulosic material, of the de-acidified
carbohydrate-comprising hydrolyzate and of the at least one primary
lignin product are M1, M2 and M3, respectively, and (M2+M3)/M1 is
greater than 0.85, greater than 0.90 or even greater than 0.95.
[0258] In some embodiments, lignocellulosic material comprises
extractives and the de-acidified lignin includes at least 50% of
the said extractives.
[0259] In some embodiments, the method includes extracting the
lignocellulosic material. In some embodiments, the extracting
includes contacting with an organic solvent. In some embodiments,
the organic solvent includes acetone.
[0260] According to various embodiments, the thermal treatment is
conducted at a temperature in the range between 350.degree. C. and
1,000.degree. C. Alternatively or additionally, the thermal
treatment is conducted at a pressure above 10 MPa, above 30 MPa and
or even above 50 MPa. Alternatively or additionally, the thermal
treatment is conducted in an atmosphere comprising less than 5%
volume of oxygen, less than 3% volume of oxygen, or even less than
1% volume of oxygen.
[0261] In some embodiments, the method includes combining at least
a fraction of the de-acidified, carbohydrate-comprising hydrolyzate
with at least a fraction of the at least one primary lignin product
to form a mixture and processing at least one of said carbohydrate
hydrolyzate and said primary lignin product in said mixture.
[0262] In some embodiments, the method further includes reacting
the hydrolyzate product with at least one of the primary lignin
product and the secondary lignin product.
[0263] In some embodiments, the processing of carbohydrate
hydrolyzate generates a carbon-containing co-product, and the
method further includes combining the co-product with the
de-acidified lignin stream to form a combined product, which
combined product is then thermally treated.
[0264] A broad aspect of the invention relates to hydrolysis of
biomass.
[0265] One aspect of some embodiments of the invention relates to
supercritical, near-critical, or sub-critical fluids to pre-treat
and/or hydrolyze the biomass.
[0266] In some exemplary embodiments of the invention, the
supercritical, near-critical, or sub-critical fluids include water
and at least one of SO.sub.2 and a solvent. In some embodiments,
the solvent is water-miscible and does not form an azeotrope with
water.
[0267] In some exemplary embodiments of the invention, there is
provided a method for the continuous treatment of biomass
comprising: a pretreatment step, wherein the biomass is contacted
with a first supercritical, near-critical, or sub-critical fluid to
form a solid matrix and a first liquid fraction; wherein the first
supercritical or near-critical fluid comprises water and at least
one of SO.sub.2 and a solvent; and wherein the solvent is
water-miscible and does not form an azeotrope with water; and a
hydrolysis step, wherein the solid matrix is contacted with a
second supercritical or near-critical fluid to produce a second
liquid fraction and an insoluble lignin-containing fraction.
[0268] In some exemplary embodiments of the invention, there is
provided a method for the continuous treatment of biomass
comprising: a pretreatment step, wherein the biomass is contacted
with a first supercritical, near-critical, or sub-critical fluid to
form a solid matrix and a first liquid fraction; and a hydrolysis
step, wherein the solid matrix is contacted with a second
supercritical or near-critical fluid to produce a second liquid
fraction and an insoluble lignin-containing fraction; wherein the
second supercritical or near-critical fluid comprises water and at
least one of SO.sub.2 and a solvent; and wherein the solvent is
water-miscible and does not form an azeotrope with water.
[0269] In some exemplary embodiments of the invention, there is
provided a method for the continuous treatment of biomass
comprising: a pretreatment step, wherein the biomass is contacted
with a first supercritical, near-critical, or sub-critical fluid to
form a solid matrix and a first liquid fraction; wherein the first
supercritical or near-critical fluid comprises water and at least
one of SO.sub.2 and a solvent; wherein the solvent is
water-miscible and does not form an azeotrope with water: and a
hydrolysis step, wherein the solid matrix is contacted with a
second supercritical or near-critical fluid to produce a second
liquid fraction and an insoluble lignin-containing fraction;
wherein the second supercritical or near-critical fluid comprises
water and at least one of SO.sub.2 and a solvent; and wherein the
solvent is water-miscible and does not form an azeotrope with
water.
[0270] In some exemplary embodiments of the invention, there is
provided a method of processing biomass comprising: a pretreatment
step, wherein the biomass is contacted with a first supercritical,
near-critical, or sub-critical fluid to form a pretreated slurry
comprising a solid matrix and a first liquid fraction comprising
xylo-oligosaccharides; wherein the first supercritical or
near-critical fluid comprises water and at least one of SO.sub.2
and a solvent; and wherein the solvent is water-miscible and does
not form an azeotrope with water; a first separation step, wherein
the solid matrix and the first liquid fraction are separated; a
first hydrolysis step, wherein the solid matrix is contacted with a
second supercritical or near-critical fluid to form an insoluble
lignin-containing fraction and a second liquid fraction comprising
cello-oligosaccharides; a second separation step, wherein the
insoluble lignin-containing fraction and the second liquid fraction
are separated; and a second hydrolysis step, wherein the second
liquid fraction is contacted with a third near-critical or
sub-critical fluid to form a product comprising glucose monomers;
and wherein the third near-critical or sub-critical fluid comprises
water and, optionally, acid.
[0271] In some exemplary embodiments of the invention, there is
provided a method of processing biomass comprising: a pretreatment
step, wherein the biomass is contacted with a first supercritical,
near-critical, or sub-critical fluid to form a pretreated slurry
comprising a solid matrix and a first liquid fraction comprising
xylo-oligosaccharides; a first separation step, wherein the solid
matrix and the first liquid fraction are separated; a first
hydrolysis step, wherein the solid matrix is contacted with a
second supercritical or near-critical fluid to form an insoluble
lignin-containing fraction and a second liquid fraction comprising
cello-oligosaccharides; wherein the first supercritical or
near-critical fluid comprises water and at least one of SO.sub.2
and a solvent; and wherein the solvent is water-miscible and does
not form an azeotrope with water; a second separation step, wherein
the insoluble lignin-containing fraction and the second liquid
fraction are separated; and a second hydrolysis step,
[0272] wherein the second liquid fraction is contacted with a third
near-critical or sub-critical fluid to form a product comprising
glucose monomers; and wherein the third near-critical or
sub-critical fluid comprises water and, optionally, acid.
[0273] In some exemplary embodiments of the invention, there is
provided a method of processing biomass comprising: a pretreatment
step, wherein the biomass is contacted with a first supercritical,
near-critical, or sub-critical fluid to form a pretreated slurry
comprising a solid matrix and a first liquid fraction comprising
xylo-oligosaccharides; wherein the first supercritical or
near-critical fluid comprises water and at least one of SO.sub.2
and a solvent; wherein the solvent is water-miscible and does not
form an azeotrope with water; a first separation step, and wherein
the solid matrix and the first liquid fraction are separated a
first hydrolysis step, wherein the solid matrix is contacted with a
second supercritical or near-critical fluid to form an insoluble
lignin-containing fraction and a second liquid fraction comprising
cello-oligosaccharides; wherein the first supercritical or
near-critical fluid comprises water and at least one of SO.sub.2
and a solvent; wherein the solvent is water-miscible and does not
form an azeotrope with water; a second separation step, and wherein
the insoluble lignin-containing fraction and the second liquid
fraction are separated; and a second hydrolysis step, wherein the
second liquid fraction is contacted with a third near-critical or
sub-critical fluid to form a product comprising glucose monomers;
and wherein the third near-critical or sub-critical fluid comprises
water and, in some embodiments, acid.
[0274] In some embodiments, the first supercritical, near-critical,
or sub-critical fluid comprises at least 100 ppm, at least 500 ppm,
at least 1,000 ppm or even at least 2,000 ppm SO.sub.2.
[0275] In some embodiments, the first supercritical, near-critical,
or sub-critical fluid comprises less than 10%, less than 8%, less
than 6%, or even less than 4% SO.sub.2.
[0276] In some embodiments, the second supercritical,
near-critical, or sub-critical fluid comprises at least 100 ppm, at
least 500 ppm, at least 1,000 ppm or even at least 2,000 ppm
SO.sub.2.
[0277] In some embodiments, the second supercritical,
near-critical, or sub-critical fluid comprises less than 10%, less
than 8%, less than 6%, or even less than 4% SO.sub.2.
[0278] In some embodiments, the solvent is acetone.
[0279] In some embodiments, the first supercritical, near-critical,
or sub-critical fluid comprises at least 10%, at least 20%, at
least 30%, at least 40%, at least 50% or even at least 60%
solvent.
[0280] In some embodiments, the second supercritical or
near-critical comprises at least 10%, at least 20%, at least 30%,
at least 40%, at least 50% or even at least 60% solvent.
[0281] In some embodiments, the pretreatment step occurs at a
temperature and pressure below the critical point of at least one
component of the first supercritical, near-critical, or
sub-critical fluid.
[0282] In some embodiments, the pretreatment step is performed at a
temperature of about 100.degree. C. to about 300.degree. C.
[0283] In some embodiments, the pretreatment step is performed at a
pressure of about 30 bar to about 115 bar.
[0284] In some embodiments, the method includes a first separation
step after the pretreatment step and prior to the hydrolysis step,
wherein the solid matrix and the first liquid fraction are
separated.
[0285] In some embodiments, the first separation step is performed
using an extruder or centrifugal press.
[0286] In some embodiments, the first liquid fraction comprises
xylose oligosaccharides.
[0287] In some embodiments, the first liquid fraction comprises an
amount of xylose oligosaccharides greater than about 50% of the
maximum theoretical yield.
[0288] In some embodiments, the pretreatment step is
continuous.
[0289] In some embodiments, the second fluid is a supercritical or
near-critical fluid, and does not include an acid.
[0290] In some embodiments, the hydrolysis step occurs at a
temperature and pressure above the critical point of at least one
component of the second supercritical or near-critical fluid.
[0291] In some embodiments, the hydrolysis step occurs at a
temperature from about 150.degree. C. to about 450.degree. C.
[0292] In some embodiments, the hydrolysis step occurs at a
pressure of about 100 bar to about 250 bar.
[0293] In some embodiments, the hydrolysis step is continuous.
[0294] In some embodiments, the solid matrix is kept at a
temperature of about 100.degree. C. or higher from the beginning of
the pretreatment step through at least the end of the hydrolysis
step.
[0295] In some embodiments, the method includes a second separation
step after the hydrolysis step, wherein the lignin fraction and the
second liquid fraction are separated.
[0296] In some embodiments, the method includes a second hydrolysis
step wherein the second liquid fraction is contacted with a third
near-critical or sub-critical fluid to produce a third liquid
fraction comprising glucose monomers; and wherein the third
near-critical or sub-critical fluid comprises water and, In some
embodiments, acid.
[0297] In some embodiments, the second hydrolysis step occurs at a
temperature of about 150.degree. C. to about 320.degree. C.
[0298] In some embodiments, the second hydrolysis step occurs at a
pressure of about 20 bar to about 90 bar.
[0299] In some embodiments, the acid is present in a catalytic
amount.
[0300] In some embodiments, the acid is present in an amount less
than about 1%.
[0301] In some embodiments, the acid is selected from the group
consisting of hydrofluoric acid, hydrochloric acid, hydrobromic
acid, hydroiodic acid, sulfuric acid, sulfonic acid, phosphoric
acid, phosphonic acid, nitric acid, nitrous acid, and combinations
thereof.
[0302] In some embodiments, the second liquid fraction has a
residence time of about 1 second to about 30 seconds in the second
hydrolysis step.
[0303] In some embodiments, the third liquid fraction comprises
glycolaldehyde.
[0304] In some embodiments, the glycolaldehyde is present in an
amount at least 10% of the theoretical maximum yield.
[0305] In some embodiments, the pressure exerted on the solid
matrix is reduced to about 105 kPa or less after the hydrolysis
step.
[0306] In some embodiments, the method includes after the
hydrolysis step, reducing the pressure exerted on the solid matrix
such that the lignin precipitates.
[0307] In some embodiments, the method includes: a
xylo-oligosaccharide hydrolysis step, wherein the first liquid
fraction is contacted with a fourth near-critical or sub-critical
fluid to produce a fourth liquid fraction comprising xylose
monomers; and wherein the fourth near-critical or sub-critical
fluid comprises water and, In some embodiments, an acid.
[0308] In some embodiments, the acid is selected from the group
consisting of hydrofluoric acid, hydrochloric acid, hydrobromic
acid, hydroiodic acid, sulfuric acid, sulfonic acid, phosphoric
acid, phosphonic acid, nitric acid, nitrous acid, and combinations
thereof.
[0309] In some embodiments, the acid is present in an amount less
than about 1%.
[0310] In some embodiments, the xylo-oligosaccharide hydrolysis
step occurs at a temperature of about 150.degree. C. to about
320.degree. C.
[0311] In some embodiments, the xylo-oligosaccharide hydrolysis
step occurs at a pressure of about 20 bar to about 90 bar.
[0312] In some embodiments, the method includes a third hydrolysis
step, wherein the first liquid fraction is contacted with a fourth
near-critical or sub-critical fluid to form a second product
comprising xylose monomers; and wherein the fourth near-critical or
sub-critical fluid comprises water and, In some embodiments,
acid.
[0313] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. Although
suitable methods and materials are described below, methods and
materials similar or equivalent to those described herein can be
used in the practice of the present invention. In case of conflict,
the patent specification, including definitions, will control. All
materials, methods, and examples are illustrative only and are not
limiting.
[0314] As used in this specification and the accompanying claims
the term "supercritical fluid" is a fluid at a temperature above
its critical temperature and at a pressure above its critical
pressure. A supercritical fluid exists at or above its "critical
point," the point of highest temperature and pressure at which the
liquid and vapor (gas) phases can exist in equilibrium with one
another. Above critical pressure and critical temperature, the
distinction between liquid and gas phases disappears. A
supercritical fluid possesses approximately the penetration
properties of a gas simultaneously with the solvent properties of a
liquid. Accordingly, supercritical fluid extraction has the benefit
of high penetrability and good solvation.
[0315] Reported critical temperatures and pressures include: for
pure water, a critical temperature of about 374.2.degree. C., and a
critical pressure of about 221 bar. Carbon dioxide has a critical
point of about 31.degree. C. and about 72.9 atmospheres (about 1072
psig). Ethanol has a critical point of about 243.degree. C. and
about 63 atmospheres. Methanol has a critical point of about
239.degree. C. (512.8 K) and about 1174.0 psia (80.9 bar). The
critical point for other alcohols can be ascertained from the
literature or experimentally.
[0316] Near-critical water has a temperature at or above about
300.degree. C. and below the critical temperature of water
(374.2.degree. C.), and a pressure high enough to ensure that all
fluid is in the liquid phase.
[0317] Sub-critical water has a temperature of less than about
300.degree. C. and a pressure high enough to ensure that all fluid
is in the liquid phase. Sub-critical water temperature may be
greater than about 250.degree. C. and less than about 300.degree.
C., and in many instances sub-critical water has a temperature
between about 250.degree. C. and about 280.degree. C.
[0318] As used herein, a fluid which is "supercritical" (e.g.
supercritical water, supercritical ethanol, supercritical CO.sub.2,
etc.) indicates a fluid which would be supercritical if present in
pure form under a given set of temperature and pressure conditions.
For example, "supercritical water" indicates water present at a
temperature of at least about 374.2.degree. C. and a pressure of at
least about 221 bar, whether the water is pure water, or present as
a mixture (e.g. water and ethanol, water and CO.sub.2, etc). Thus,
for example, "a mixture of sub-critical water and supercritical
carbon dioxide" indicates a mixture of water and carbon dioxide at
a temperature and pressure above that of the critical point for
carbon dioxide but below the critical point for water, regardless
of whether the supercritical phase contains water and regardless of
whether the water phase contains any carbon dioxide. For example, a
mixture of sub-critical water and supercritical CO.sub.2 may have a
temperature of about 250.degree. C. to about 280.degree. C. and a
pressure of at least about 225 bar.
[0319] As used in this specification and the accompanying claims
the term "solid matrix" indicates a composition comprising a solid
or particulate component.
[0320] As used in this specification and the accompanying claims
the term "liquid fraction" indicates a liquid comprising at least
one component which is a product of a reaction or treatment step.
For example and without limitation, a liquid fraction after a
hydrolysis step may include a product of the hydrolysis step with
unreacted components and/or one or more additional products or
by-products of the hydrolysis step and/or one or more products of a
prior treatment step.
[0321] As used in this specification and the accompanying claims
the term "continuous" indicates a process which is uninterrupted
for its duration, or interrupted, paused or suspended only
momentarily relative to the duration of the process. Treatment of
biomass is "continuous" when biomass is fed into the apparatus
without interruption or without a substantial interruption, or
processing of said biomass is not done in a batch process.
[0322] As used in this specification and the accompanying claims
the term "resides" indicates the length of time which a given
portion or bolus of material is within a reaction zone or reactor
vessel.
[0323] As used herein, the terms "comprising" and "including" or
grammatical variants thereof are to be taken as specifying
inclusion of the stated features, integers, actions or components
without precluding the addition of one or more additional features,
integers, actions, components or groups thereof.
[0324] Throughout this specification and the accompanying claims,
percentages (%) of chemicals are W/W (weight per weight) unless
otherwise indicated. In those cases where the weight percent is
calculated relative to part of the composition, e.g. relative to
the water component, the definition is provided explicitly, e.g.
the weight percent of hydrochloric acid in an aqueous mixture may
be provided by 100.times.HCl/(HCl+Water), by weight in a given
sample of the mixture.
INCORPORATION BY REFERENCE
[0325] All publications, patents, and patent applications mentioned
in this specification are herein incorporated by reference to the
same extent as if each individual publication, patent, or patent
application was specifically and individually indicated to be
incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0326] In order to understand the invention and to see how it may
be carried out in practice, embodiments will now be described, by
way of non-limiting example only, with reference to the
accompanying figures. In the figures, identical and similar
structures, elements or parts thereof that appear in more than one
figure are generally labeled with the same or similar references in
the figures in which they appear. Dimensions of components and
features shown in the figures are chosen primarily for convenience
and clarity of presentation and are not necessarily to scale. The
attached figures are:
[0327] FIG. 1 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention;
[0328] FIG. 2 is a simplified flow diagram of a method according to
some exemplary embodiments of the depicting the extraction portion
of the method in greater detail;
[0329] FIG. 3 is a schematic diagram of a system according to some
exemplary embodiments of the invention;
[0330] FIG. 4 is a graph of total solids/dry wood wt % as a
function of time for different treatments associated with various
exemplary embodiments of the invention;
[0331] FIG. 5 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention;
[0332] FIGS. 6a and 6b are simplified flow diagrams of methods
according to some exemplary embodiments of the invention;
[0333] FIG. 7 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention;
[0334] FIG. 8 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention;
[0335] FIG. 9 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention; and
[0336] FIGS. 10a and 10b are schematic flow schemes of methods
according to various exemplary embodiments of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0337] Embodiments of the invention relate to systems and methods
for processing lignocellulosic materials.
[0338] Specifically, some embodiments of the invention can be used
to pre-treat lignocellulosic substrates prior to hydrolysis or a
direct conversion process.
[0339] In some embodiments, this pre-treatment removes impurities
present in the substrate which are not hydrolysis and/or direct
conversion substrates. In some exemplary embodiments of the
invention, this removal contributes to a decrease in downstream
processing difficulties caused by the impurities. These
difficulties may be associated with, for example, buildup of
impurities on moving parts and/or clogging of passages (e.g.
filters and/or nozzles) The impurities include, but are not limited
to, ash (e.g. calcium and/or magnesium) and lipophilic material.
Exemplary lipophilic materials are described below.
[0340] In some exemplary embodiments, the extracted substrate is
hydrolyzed to form a liquid hydrolyzate and residual lignin solids.
According to some exemplary embodiments, following hydrolysis, the
lignin solids are separated from the hydrolyzate by filtration. In
some exemplary embodiments of the invention, extraction of the
lignocellulosic material prior to the hydrolysis contributes to an
improvement in filtration rate (i.e. makes the liquid hydrolyzate
go through the filter faster).
[0341] The principles and operation of systems and/or methods
according to exemplary embodiments of the invention may be better
understood with reference to the drawings and accompanying
descriptions. Drawings are referred to in an order that is believed
to most clearly explain the accompanying claims. FIG. 4 includes
experimental data and is referred to in the Examples section.
[0342] Before explaining at least one embodiment of the invention
in detail, it is to be understood that the invention is not limited
in its application to the details set forth in the following
description or exemplified by the examples. The invention is
capable of other embodiments or of being practiced or carried out
in various ways. Also, it is to be understood that the phraseology
and terminology employed herein is for the purpose of description
and should not be regarded as limiting.
Exemplary System Overview
[0343] FIG. 3 is a schematic representation of a system, indicated
generally as 300, according to various exemplary embodiments of the
invention.
[0344] Depicted exemplary system 300 includes an extraction module
310 adapted to extract a lignocellulosic substrate 100 with an
extractant 110. Optionally, commercially available extraction
equipment such as a Continuous Loop, Shallow Bed Extractor
available from Crown Iron Works (Minneapolis, Minn., USA) is
employed in extraction module 310. In some exemplary embodiments of
the invention, extractant 110 includes a water-soluble organic
solvent (e.g. acetone and/or ethanol). In some embodiments,
extractant 110 includes a weak acid (e.g. sulfurous acid and/or
acetic acid and/or phosphorous acid). Module 310 outputs an
extracted substrate 140 and miscella 130. The term "miscella" as
used in the specification and the accompanying claims indicates an
extractant containing suspended particles and/or dissolved
materials and/or liquids extracted from substrate. In some
instances a miscella is an emulsion.
[0345] The quantitative and/or qualitative composition of miscella
130 will vary depending upon substrate 100 and extractant 110.
According to various exemplary embodiments of the invention,
miscella 130 can include resin(s) and/or pitch and/or tall oil(s)
and/or terpene(s) and/or other volatile organic compound(s) and/or
proteinaceous materials and/or ash. The quantitative composition of
miscella 130 may also vary depending upon extraction
conditions.
[0346] According to some exemplary embodiments, extraction module
310 performs extraction which is carried out at a temperature above
ambient, greater than 30.degree., 40.degree., 50.degree.,
60.degree., or 70.degree. C. Alternatively or additionally,
extraction module 310 performs extraction which occurs at a
temperature less than 70.degree., 60.degree., 50.degree.,
40.degree. or 30.degree. C. In some exemplary embodiments of the
invention, extraction is carried out at a temperature in the range
of from about 30.degree. to about 80.degree. C., from about
40.degree. to about 70.degree. C., or from about 50.degree. to
about 60.degree. C. Optionally, increasing the temperature of
extraction 310 can contribute to an increase in efficiency of
extraction of one or more components of substrate 100.
[0347] In order to perform the extraction, module 310 receives
lignocellulosic substrate 100 and extractant 110 separately and/or
together as is illustrated by FIG. 3 and brings them into contact
with one another. Optionally, module 310 includes a mixing
apparatus (not depicted) to contribute to efficiency of this
contact. In some exemplary embodiments of the invention, the mixing
apparatus circulates extractant 110 through substrate 100 (e.g. by
pumping and/or spraying).
[0348] Depicted exemplary system 300 includes a hydrolysis module
320 adapted to receive extracted substrate 140, or a dried version
of extracted substrate 140 and contact it with an acid 321.
Optionally, hydrolysis module 320 is adapted for acid hydrolysis.
Exemplary acids that can be used are mineral acids, such as
hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, and
combinations thereof. In some exemplary embodiments, the mineral
acid includes HCl and/or H.sub.2SO.sub.4. Optionally, concentration
of the acid is 20, 30, 35, 37, 39, 41, 43 or 45% or intermediate or
greater percentages. Hydrolysis module 320 produces hydrolyzate
270.
[0349] Various hydrolysis modules suitable for use in the context
of module 320 are disclosed in, for example, co-pending application
PCT/US11/57552 "HYDROLYSIS SYSTEMS AND METHODS" to JANSEN et al.
filed on Oct. 24, 2011; which is fully incorporated herein by
reference. In some embodiments, hydrolysis module 320 includes a
single reactor with a countercurrent flow zone and a co-current
flow zone and a trickling bed re-circulation system.
[0350] In some embodiments, system 300 includes a dryer 330 which
removes residual extractant from extracted substrate 140. Dryer 330
may be, for example, a toaster-dryer. Commercially available
toaster dryers suitable for use in this context include, but are
not limited to, a Desolventizer-Toaster-Dryer-Cooler from the Crown
Iron Works Company (Minneapolis, Minn., USA) and/or Barr-Rosin
(Maidenhead, Berkshire; UK). Alternatively or additionally, dryer
330 may include a flash dryer. Optionally, a flash dryer can be
used for a second removal. Optionally, residual extractant removed
by dryer 330 is combined with miscella 130. In some exemplary
embodiments of the invention, dryer 330 receives steam discharged
(not shown) from disruption module 340. Optionally, this steam
serves as a heat source. In some exemplary embodiments of the
invention, this heat source is used to evaporate additional solvent
from extracted substrate 140 prior to entry into hydrolysis module
320.
[0351] In some exemplary embodiments of the invention, system 300
includes a disruption module 340 adapted to apply a predetermined
pressure-temperature-time profile to lignocellulosic substrate 100
to produce a disrupted substrate 105. According to various
exemplary embodiments, disruption module 340 includes a plug screw
feeder (also known as an expeller or expeller press) and/or a steam
explosion (SE) reactor. Details on exemplary commercially available
equipment to deliver such a predetermined pressure-temperature-time
profile are provided in the section entitled "Exemplary
Thermo-mechanical Treatment". According to various exemplary
embodiments of the invention, disruption causes a breakdown in the
microstructure of the lignocellulosic substrate, without an
appreciable change in the macrostructure. In those embodiments
where optional disruption module 340 is present, disrupted
substrate 105 proceeds to extraction module 310.
[0352] In some exemplary embodiments of the invention, system 300
includes a distillation column 350 which receives miscella 130 and
returns at least a portion of the solvent to extraction module 310
as indicated by an arrow. Alternatively or additionally,
distillation column 350 separates impurities from miscella 130 and
produces a lipophilic fraction 170 and an aqueous phase 160
comprising hydrocarbons. Optionally, lipophilic fraction 170 is
processed to recover desired components (e.g. tall oils and/or
resins). Various components in lipophilic fraction 170 can be used
to produce adhesives, rubbers, inks, emulsifiers (e.g. in asphalt),
cement binders, soaps, lubricants, as a component of a drilling
fluid and in oil based varnishes.
[0353] In some exemplary embodiments of the invention, distillation
column 350 includes commercially available equipment. Suitable
equipment may be purchased, for example, from Applied Process
Technology, Inc. (Cincinnati, Ohio; USA)
[0354] In some embodiments, distillation column 350 includes
multiple columns. For example, distillation column 350 may include
a miscella column, an acetone column and a pitch column. The
miscella column can use an applied vacuum to remove 60% or more of
the acetone out the top as a mixture containing VOCs (volatile
organic compounds) and water. This acetone can continue to an
acetone column and material remaining in the acetone column bottom
may be directed to a pitch column.
[0355] According to these embodiments, the acetone column processes
the mixture from the top of the miscella column under vacuum. The
acetone leaves the acetone column through the top; the VOCs come
out the middle; and the residual water/acetone mixture leaves
through the bottom and goes to the pitch column.
[0356] In these embodiments, the pitch column boils the residual
water/acetone mixture under slight negative pressure, until the
acetone and a small fraction of the water come out the top leaving
the tall oils and remaining water in the bottom. The insoluble
fraction is separated from the soluble fraction by mechanical means
such as decantation and/or filtration and/or centrifugation.
[0357] In some exemplary embodiments of the invention, aqueous
phase 160 is routed to a methane generator 360. Optional methane
generator 360 can use anaerobic digestion to produce methane. In
some exemplary embodiments of the invention, methane from generator
360 serves as a fuel source for system 300 (e.g. to heat
distillation column 350) and/or as fuel in a context not directly
related to system 300. Optionally, methane from generator 360
supplements additional fuels originating outside system 300.
[0358] In some exemplary embodiments of the invention, aqueous
phase 160 is filtered prior to anaerobic digestion, for example,
using an ultra-filtration membrane. Aqueous phase 160 is
alternatively or additionally subjected to sulfate reduction, for
example, by liming and separation of the formed gypsum.
Exemplary Method
[0359] FIG. 1 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention generally depicted as
101.
[0360] Depicted exemplary method 101 includes providing a
lignocellulosic substrate 100 (e.g. wood) and contacting or
extracting 120 the substrate with an extractant 110. According to
various exemplary embodiments of the invention contacting or
extracting 120 is conducted at a temperature of about 30.degree. to
about 80.degree. C., optionally about 40.degree. to about
70.degree. C., optionally about 50.degree. to about 60.degree.
C.
[0361] In some exemplary embodiments of the invention, extractant
110 includes a water-soluble organic solvent. Optionally,
extractant 110 includes a weak acid. Extracting 120 produces, after
separation, an extracted substrate 140, and a miscella 130. In the
depicted exemplary embodiment, miscella 130 is initially removed
from extracted substrate 140 passively, for example by draining. In
depicted exemplary method 101, additional miscella 240 is removed
from extracted substrate 140 to form dried extracted substrate 230
and additional miscella 240. Optionally, removal of additional
miscella 240 is performed by drying 221. Drying 221 may include one
or more forms of active removal including, but not limited to,
heating (e.g. with steam) and/or centrifugation and/or pressing. In
some embodiments, dried extracted substrate 230 is substantially
de-solventized by drying 221.
[0362] Additional miscella 240 and miscella 130 each optionally
comprise VOCs impurities and/or water and/or weak acid and/or
solvent. In the depicted exemplary embodiment of the invention,
additional miscella 240 is combined with miscella 130 for further
processing. Optionally, miscellae 130 and 240 can be processed
separately.
[0363] In some exemplary embodiments of the invention, method 101
includes hydrolyzing 250 of separated extracted substrate 140
and/or dried extracted substrate 230. According to various
exemplary embodiments of the invention hydrolyzing 250 includes a
chemically catalyzed process and/or an enzymatically catalyzed
process. In some embodiments, chemically catalyzed processes employ
a catalyst including a mineral acid (e.g. HCl and/or
H.sub.2SO.sub.4) and/or a reactive fluid. In some embodiments,
hydrolyzing 250 includes enzymatically hydrolyzing extracted
substrate 140 and/or dried extracted substrate 230 using one or
more enzymes.
[0364] Hydrolyzing 250 produces a hydrolyzate 270 rich in sugars
and also produces a stream of residual lignin 260 including lignin
solids. Thus, extracting 120 may be viewed as a "pre-treatment" of
substrate 100 to remove impurities which could potentially
complicate hydrolysis 250. In some embodiments, method 101 includes
filtering lignin solids from hydrolyzate 270. According to these
embodiments of the invention, extracting 120 contributes to an
increase in a rate of this filtration. In some exemplary
embodiments of the invention, a filtration rate of filtering lignin
solids from hydrolyzate 270 is faster by at least 10% compared with
a filtration rate of lignin solids from hydrolyzate formed by
hydrolyzing the substrate without extracting 120, using an
identical filter and identical filtration conditions.
[0365] In other exemplary embodiments of the invention, a thermal
process involving exposure to temperatures in excess of 200.degree.
C. is substituted for hydrolysis 250. Exemplary thermal processes
involving exposure to temperatures in excess of 200.degree. C.
include, but are not limited to pyrolysis and gasification
According to various exemplary embodiments of the invention the
pretreatment contributes to a reduction in complications in
downstream processing of hydrolyzate 270 and/or lignin stream 260
and/or products of pyrolysis and/or products of gasification.
[0366] In some embodiments, the method includes subjecting
extracted substrate 140 and/or 230 to a sulfite process.
[0367] In some embodiments, the sulfite process includes reacting
the substrate with calcium sulfite at a pH of about 1 to about 2
and/or with magnesium sulfite at a pH of about 3 to about 5.
Optionally, the reaction is carried out at a temperature of at
least 115.degree., 125.degree., 130.degree., 140.degree.,
145.degree. or even 150.degree. C. or more. In some embodiments,
the reaction time is about 3, 4, 5, 6 or even 7 hours or more.
These conditions can cause sulfonation and/or hydrolysis and/or
condensation. Alternatively, some sulfite processes operate under
neutral or alkaline conditions using sodium or ammonia as base.
Additional details on sulfite processes can be found in Saake, B.
and Lehnen, R. (2007) Lignin in Ullmann's Encyclopedia of
Industrial Chemistry [available at
http://onlinelibraryDOTwileyDOTcom/doi/10.1002/14356007.a15.sub.--305.pub-
3/full]; which is fully incorporated herein by reference.
Exemplary Thermo-Mechanical Treatment
[0368] In some embodiments of the invention, method 101 includes a
thermo-mechanical treatment 103. Optionally, treatment 103 disrupts
substrate 100 by applying a predetermined pressure-temperature-time
profile. According to these embodiments, the resultant disrupted
substrate 105 is then subjected to extracting 120. According to
some embodiments, the predetermined pressure-temperature-time
profile is applied prior to extracting 120 of disrupted substrate
105. According to some embodiments, the resulting extracted
disrupted substrate 140 is then subjected to downstream processing,
as described hereinbelow.
[0369] In some exemplary embodiments of the invention, treatment
103 influences extracting 120. For example, physical disruption of
substrate 100 may contribute to an increase of penetration of
extractant 110 into disrupted substrate 105 (relative to substrate
100 under similar extraction conditions) during extracting 120.
Optionally, this increase in penetration contributes to an increase
in efficiency of extraction of one or more materials in the
substrate. Alternatively or additionally, a proportion of
extractant 110 recovered passively (e.g. by draining) as miscella
130, relative to the amount recovered actively (e.g. by
centrifugation) as additional miscella 240 may be higher if
treatment 103 is performed. Alternatively or additionally, a total
amount of extractant 110 recovered as miscella 130 and additional
miscella 240 may be higher if treatment 103 is performed. For
example, in some instances at least 5, 10, 15, 20, 25, 30, 35, 40,
45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95% of extractant 110 is
recoverable through the processes described herein.
[0370] In some exemplary embodiments of the invention,
thermo-mechanical treatment 103 includes a steam explosion
treatment, and/or ammonia fiber explosion treatment. Optionally,
the steam explosion treatment includes application of steam for a
period of from about 30 seconds to about 3 minutes, such as, for
example, about 30, 45, 60, 75, 90, 100, 110, 120, 150, 180 seconds,
or intermediate or longer periods of time. According to some
exemplary embodiments of the invention, steam is applied for a
period of from about 45 to about 120 seconds. According to various
exemplary embodiments of the invention steam is applied at a
temperature of about 190.degree., 195.degree., 200.degree.,
205.degree., or 210.degree. C. or intermediate or greater
temperatures. According to various exemplary embodiments of the
invention steam is applied at a pressure of about 10, 11, 12, 13,
14 or 15 atmospheres or intermediate or greater pressures.
[0371] Treatment 103 can be ended by an abrupt discharge of
pressure (venting) to return the substrate to ambient pressure and
rapidly cool the substrate. Abrupt discharge can be accomplished by
release of the substrate through an opening (nozzle), to form
disrupted substrate 105. Steam explosion equipment is available
commercially, for example from Andritz AG (Graz, Austria). In some
exemplary embodiments of the invention, steam explosion is
performed using an autoclave and venting the steam pressure
suddenly to cause substrate explosion.
[0372] Alternatively or additionally, some exemplary embodiments of
the invention employ an expeller, such as a plug screw feeder to
thermo-mechanically treat 103 the substrate 100. An example of a
commercial plug screw feeder amenable to incorporation into various
exemplary embodiments of the invention is an Impressafiner (Andritz
AG; Graz, Austria). Alternatively, Ajax LynFlow.TM. Plug Seal Screw
Feeders (Ajax Equipment; Bolton, UK) can be employed. Plug screw
feeders are also manufactured by MST corporation (Prineville,
Oreg., USA).
[0373] In some exemplary embodiments of the invention, two or more
predetermined pressure-temperature-time profiles are applied. For
example, steam explosion, followed by a plug screw feeder.
[0374] In some exemplary embodiments of the invention, downstream
processing of extracted disrupted substrate 140 includes at least
one of hydrolysis 250, pyrolysis, and gasification.
[0375] In some exemplary embodiments, hydrolysis 250 comprises
hydrolysis in the presence of at least one of a reactive fluid,
and/or a mineral acid to produce soluble sugars. According to
various exemplary embodiments of the invention these soluble sugars
can serve as an energy source in aerobic respiration and/or
anaerobic respiration and/or fermentation.
[0376] As used in this specification and the accompanying claims
the term "reactive fluid" is defined as a fluid that is at a
temperature higher than the boiling point of the liquid state of
the fluid under atmospheric pressure (1 atm). The reactive fluid
may be a liquid, a gas, a supercritical fluid, or a mixture of
these. For example, water at a temperature above 100.degree. C. and
under atmospheric pressure is considered a reactive fluid.
Supercritical, near critical, and sub-critical fluids are reactive
fluids, illustrative examples including but not limited to
sub-critical water, near critical water, supercritical water,
supercritical ethanol, and supercritical CO.sub.2.
[0377] Use of reactive fluids in the context of hydrolysis of
lignocellulose is described in WO 2010/009343 which is fully
incorporated herein by reference.
[0378] In some exemplary embodiments, the mineral acid comprises at
least one of hydrochloric acid, sulfuric acid, nitric acid,
phosphoric acid. In some exemplary embodiments of the invention,
the mineral acid is hydrochloric acid. In other exemplary
embodiments of the invention, the mineral acid is sulfuric
acid.
[0379] In some exemplary embodiments, hydrolysis 250 comprises
enzymatic hydrolysis to produce soluble sugars. Materials removed
by extractant 110 might interfere with enzymatic activity if
present during the enzymatic reaction.
[0380] According to various exemplary embodiments of the invention
enzymes capable of hydrolyzing alpha and/or beta bonds are
used.
[0381] According to various exemplary embodiments of the invention
enzymatically hydrolyzing includes use of at least one enzyme
belonging to EC 3.2.1 according to the Nomenclature Committee of
the International Union of Biochemistry and Molecular Biology
(NC-IUBMB) Enzyme Nomenclature Recommendations. This class of
enzymes includes, but is not limited to, amylases, cellulases,
hemicellulases, transglucosidases, glucoamylases,
alpha-glucosidases and pullulanases. Optionally, an alpha amylase
and/or a beta amylase and/or a 1-4 alpha glucosidase are
employed.
[0382] It is expected that during the life of this patent many EC
3.2.1 enzymes will be characterized and the scope of the invention
is intended to include all such new enzymes a priori.
[0383] For purposes of this specification and the accompanying
claims, the term "enzyme" includes a single enzyme as well as a
mixture including two or more enzymes. Optionally, an enzyme is
provided as a crude preparation (e.g. cell extract) characterized
by a type and/or level of activity, as opposed to a precise
molecular definition. Alternatively or additionally, enzymes can be
provided by incubation with living cells (e.g. in a fermentor using
a suitable media). Optionally, specificity for a desired bond type
can be achieved by appropriate enzyme selection and/or selection of
suitable reaction conditions. In some exemplary embodiments of the
invention at least 10% of disaccharides in the mixture are
converted to monosaccharides by an enzymatic hydrolysis treatment
at 250. Alternatively or additionally, at least 10% of
oligosaccharides in a hydrolysis mixture are enzymatically
hydrolyzed at 250 to release additional monosaccharides. In some
exemplary embodiments of the invention, the enzymes are immobilized
(e.g. on beads and/or a membrane). In some exemplary embodiments of
the invention, immobilization contributes to an increase in yield
of an enzymatic hydrolysis product per unit of enzyme.
[0384] In some exemplary embodiments, lignin extracted at 120 is
less than 10%; optionally less than 5%; optionally less than 2%;
and optionally less than 1% of lignin in the substrate prior to
extraction.
Exemplary Solvent and Acid Considerations
[0385] Depicted exemplary method 101 employs an extractant
including one or more water-soluble organic solvents and optionally
includes one or more weak acids.
[0386] In some exemplary embodiments of the invention, the
water-soluble organic solvent in extractant 110 has a solubility in
water of about 40%, 50%, 60% or 70% wt or intermediate percentages
(percent weight solvent to weight water) at 25.degree. C. In some
exemplary embodiments of the invention, the solvent is fully
miscible with water.
[0387] Alternatively or additionally, in some embodiments of the
invention, water has a solubility in the solvent of at 40%, 50%,
60%, 70% wt or intermediate percentages at 25.degree. C.
[0388] In some embodiments, the water-soluble organic solvent has
solubility in water of at least 50% at 25.degree. C. and/or water
has a solubility in the solvent of at least 50% at 25.degree. C. As
used in this specification and the accompanying claims the term
"weak acid" refers to an acid having a pKa in the range of from 0
to 10, and analogs and derivatives thereof, including oxides
thereof.
[0389] In some exemplary embodiments of the invention, the weak
acid has a pKa greater than 0.1, optionally greater than 0.5 and
optionally greater than 1.0. Alternatively or additionally, the
weak acid has a pKa less than 6, optionally less than 5.5 and
optionally less than 5.0. In some exemplary embodiments of the
invention, the weak acid has a boiling point lower than 120.degree.
C., optionally lower than 100.degree. C. at atmospheric pressure.
According to some embodiments, a concentration of weak acid in the
solvent is greater than 100, 300, 700, 1,000, 1,500 or 2,000 PPM.
Alternatively or additionally, according to some embodiments, a
concentration of weak acid in the solvent is less than 20,000;
15,000; 12,000 or 10,000 PPM. In some embodiments, a concentration
of weak acid in the solvent is about 1,000 to about 15,000 PPM, or
about 2,000 to about 12,000 PPM. Optionally, a concentration of
weak acid in the solvent is optionally in the range of from about
100 to about 20,000 PPM, about 1,000 to about 15,000 PPM, or about
2,000 to about 12,000 PPM. In some exemplary embodiments of the
invention, extractant 110 is formed by adding SO.sub.2 to a mixture
of solvent and water. In some embodiments, the concentrations of
SO.sub.2 can be 0.05-5%, 0.1-4%, 0.3-3% or 0.5-2%. Alternatively or
additionally, the weak acid does not form an azeotrope with
water.
[0390] Alternatively or additionally, the solvent does not form an
azeotrope with water.
[0391] In some exemplary embodiments of the invention, a boiling
point below 100.degree. C., and/or failure to form an azeotrope
with water, contribute to ease of acid recovery. Optionally, this
makes it easier to recycle the acid for use in a subsequent
extraction 120. Optionally, only a fraction of the acid is
recovered, such that there is a need for acid make-up.
[0392] Optionally, the weak acid includes sulfurous acid and/or
acetic acid and/or phosphorous acid and/or carbonic acid.
[0393] As used herein, the term "sulfurous acid" includes SO.sub.2
as well as H.sub.2SO.sub.3. In some exemplary embodiments of the
invention, the extractant is formed by contacting SO.sub.2 with
water. In some exemplary embodiments of the invention, first
extractant 110 is formed by contacting an organic solvent and
SO.sub.2.
[0394] In some exemplary embodiments of the invention, contacting
of the organic solvent and SO.sub.2 is conducted in a vapor phase
to form a vapor mixture, which on condensation forms first
extractant 110, part Optionally, the vapor mixture includes water
vapors and the extractant formed on condensation includes water of
which reacts with SO.sub.2 to form sulfurous acid. Alternatively or
additionally, water is added after condensation. In some
embodiments, part of the water used to form the sulfurous acid is
added to first extractant 110 on contacting with water-containing
lignocellulosic material (i.e. during extracting 120).
[0395] In some embodiments, sulfurous acid is present in extractant
110 at a concentration of 500 to 10,000 PPM, optionally 1,000 to
8,000 PPM, optionally 1,500 to 7,000 PPM. These embodiments
optionally involve dissolving SO.sub.2 in an acetone/water
extractant.
[0396] In some exemplary embodiments of the invention, substrate
100 contains cations. In some embodiments, extractant 110 is
provided in an amount sufficient to provide at least 0.5, 1.0, 1.5,
2.0, or 3.0 mole of the weak acid per equivalent of cations or
intermediate or greater amounts of acid.
[0397] In some embodiments, lignocellulosic substrate 100 contains
organic acids. In some embodiments, first extractant 110 is
provided in an amount sufficient to provide at least 0.5, 1.0, 1.5,
2.0, or 3.0 mole of the weak acid per equivalent of organic acid or
intermediate or greater amounts of weak acid.
[0398] Alternatively or additionally, in some exemplary embodiments
of the invention, a ratio between the water-soluble organic solvent
(e.g., acetone) in the first extractant and water in the substrate
is at least 2.0; at least 2.5; at least 2.7; at least 2.9; or at
least 3.5 or intermediate or greater values on a weight basis.
Exemplary Extraction Considerations
[0399] Referring again to FIG. 1, extracting 120 optionally
includes two or more serial extractions. In some embodiments, each
of these two or more extractions is performed as a counter current
extraction.
[0400] In those embodiments of the invention which employ two or
more serial extractions, with counter-current contacting between
substrate 100 and extractant 110, unextracted substrate is
contacted first with used extractant that has already contacted
substrate one or more times and contains mineral ions and/or
organic matter. In some instances, 2 or more, 3 or more, 4 or more
or 5 or more serial extractions are conducted.
[0401] Following contact with this unextracted substrate, the
liquid which is separated forms miscella 130. Note that this
separation occurs after the first extraction from the standpoint of
substrate 100, although it is the last extraction in the series
from the standpoint of the extractant.
[0402] After separation of miscella 130, the lignocellulosic
substrate 100 (now partially extracted) goes through one or more
additional contacting stages and is eventually contacted with a
fresh extractant 110 (i.e. not previously used). Note that this is
the last extraction from the standpoint of substrate 100, although
it is the first extraction in the series from the standpoint of
extractant 110.
[0403] At this stage, the lignocellulosic material is separated
from the extractant as extracted substrate 140. According to
various exemplary embodiments of the invention, different forms of
separation may be employed. In some embodiments, separation of
lignocellulosic material from the extractant involves pressing
and/or decantation and/or filtration and/or centrifugation.
[0404] In some embodiments, extractant 110 is passed through two or
more contacting vessels containing substrate lignocellulosic
substrate 100. Optionally, the number of extractions 120 and/or
contacting vessels is greater than 3 and/or less than 9. In some
embodiments, the number of extractions 120 and/or contacting
vessels is 5, 6 or 7. Optionally, a number of extractions 120
and/or contacting vessels can be adjusted based upon the amount of
impurities in substrate 100, which can be determined empirically
using laboratory techniques. Alternatively or additionally,
increasing a number of extractions 120 and/or contacting vessels
contributes to an increase in efficiency of extraction with a given
volume of extractant 110.
[0405] In some exemplary embodiments of the invention, extraction
120 includes two or more extractions which are not identical to one
another. According to various exemplary embodiments of the
invention the extractions may differ in temperature conditions
and/or duiration and/or number of extraction stages and/or
extractant 110.
[0406] In some exemplary embodiments of the invention, each of said
two or more extractions is characterized by a ratio [w/w] between
the weak acid and the solvent in extractant 110 independent of a
same ratio in one or more other extractions of the two or more
extractions. In some embodiments, during modification for recycling
210 described hereinbelow, extract recycling forms an acid depleted
fraction and an acid-rich fraction that are used in said two or
more extractions.
[0407] In some exemplary embodiments of the invention, extraction
120 is performed in a continuous loop, shallow bed extractor. An
example of a commercial continuous loop, shallow bed extractor that
may be adapted for use in the context of exemplary embodiments of
the invention is the Model III Solvent Extractor (Crown Iron Works
Company; Roseville, Minn., USA).
[0408] Referring now to FIG. 2, extracting 120, including two or
more extractions is illustrated in more detail in a simplified flow
scheme. In the depicted exemplary embodiment, multi-stage
contacting with six stages and the use of extractants having
different weak acid content is diagrammed. In the diagram, flow of
substrate is downwards and flow of extractant is upwards.
[0409] FIG. 2 employs numerals similar to those used in FIG. 1 when
referring to similar materials or streams. In the depicted
embodiment, extractant is added only at stages 3 and 6. According
to the depicted embodiment, lignocellulosic substrate 100 is
contacted in stage 1 with a mixture which has already contacted
substrate in stages 2 and 3. The mixture includes acid-rich first
extractant 110B and an acid-depleted second extractant 110A. As
substrate 100 progresses to stages 2 and 3, the mixture with which
it is in contact has progressively lower concentrations of
extracted impurities.
[0410] As substrate 100 progresses to stages 4 to 6, it is serially
extracted by acid depleted extractant 110A which enters at stage 6
and flows upwards. As a result, the last extraction of substrate
100 at stage 6 is with a first extractant depleted with respect to
weak-acid.
[0411] In some embodiments, extractants 110A and/or 110B include
water. According to various exemplary embodiments of the invention
a ratio between water and solvent in each of the stages is
controlled independently, for example by controlling the amount of
extractant added in each of the stages, taking into account to the
amount of water contained in said substrate 100 in each of the
stages and in its flow rate.
Exemplary Optional Second Extraction
[0412] Referring again to FIG. 1: In some exemplary embodiments of
the invention, method 101 includes performing an additional
extraction with a second extractant which contains a water-soluble
organic solvent. According to various exemplary embodiments of the
invention this additional extractant may be with the same
extractant 110 or two different extractants may be employed (see
110A and 110B of FIG. 2). In some embodiments, differences between
the extractants may include differences in acid type and/or acid
concentration and/or solvent type and/or solvent concentration.
[0413] In some exemplary embodiments of the invention, the second
extractant comprises a lower concentration of weak acid than the
first extractant or comprises no weak acid.
[0414] In some exemplary embodiments of the invention, the second
extractant comprises organic solvent similar to that of the solvent
of the first extractant.
[0415] In some exemplary embodiments of the invention, the
additional extraction includes wetting of substrate 100 with the
second extractant prior to thermo-mechanical treatment 103.
Exemplary Processing of Extracted Substrate
[0416] As shown in FIG. 1, in some exemplary embodiments of the
invention, extracting 120 of a lignocellulosic substrate 100 with
an extractant 110 comprising a water-soluble organic solvent
produces, after removal of miscella 130, an extracted substrate
140.
[0417] In some embodiments, removal of miscella 130 comprises
passive removal, such as draining. Alternatively or additionally,
removal of miscella 130 comprises active removal, such as
centrifugation.
[0418] In some embodiments of the invention, extracted substrate
140 is hydrolyzed 250 to produce a hydrolyzate 270 rich in sugars
as well as a stream of residual lignin 260. Hydrolysis 250 may be
performed in the presence of one or more mineral acids, such as
hydrochloric acid and/or sulfuric acid and/or nitric acid and/or
phosphoric acid. In some exemplary embodiments, the mineral acid is
HCl. In other exemplary embodiments of the invention, the mineral
acid is H.sub.2SO.sub.4.
[0419] Alternatively or additionally, extracted substrate 140 may
be subjected to pyrolysis and/or gasification and/or hydrolysis in
the presence of a reactive fluid.
[0420] In some exemplary embodiments, pyrolysis comprises use of at
least one of a fixed bed reactor, an Auger reactor, an ablative
reactor, a rotating cone reactor, and a fluidized bed reactor.
[0421] In some embodiments, extractant 110 comprises a weak acid
(e.g. sulfurous acid and/or acetic acid).
[0422] In some embodiments, substrate 100 is disrupted by
application of a predetermined pressure-temperature-time profile
thereto.
[0423] In some embodiments, following extraction, extractant 110 is
separated from miscella 130.
[0424] In some embodiments, subsequent to removal of miscella 130
from extracted substrate 140, substrate 140 is subjected to a
sulfite process.
[0425] As used in this specification and the accompanying claims
the term "sulfite process" indicates any process which produces
cellulose fibers from a lignocellulosic substrate by using various
salts of sulfurous acid to extract the lignin from the substrate.
In some embodiments, the extraction is performed in large pressure
vessels called digesters. According to various exemplary
embodiments of the invention, salts used in the pulping process are
either sulfites (SO.sub.3.sup.2), or bisulfites (HSO.sub.3.sup.-),
depending on the pH. Optionally, the counter ion can be sodium (NO,
calcium (Ca.sup.2+), potassium (K.sup.+), magnesium (Mg.sup.2+) or
ammonium (NH.sub.4.sup.+).
[0426] According to various embodiments of the invention the
sulfite process is followed by hydrolyzing 250 of extracted
substrate 140 using a mineral acid as catalyst, and/or pyrolyzing
extracted substrate 140, and/or gasifying extracted substrate 140,
and/or hydrolyzing extracted substrate 140 in the presence of a
reactive fluid.
Additional Exemplary Method
[0427] FIG. 7 is a simplified flow diagram of a method of enzymatic
hydrolysis of a lignocellulosic substrate indicated generally as
method 700. Depicted exemplary method 700 includes extracting 120
lignocellulosic substrate 100 with an extractant 110 comprising a
water-soluble organic solvent. Extracting 120 produces an extracted
substrate 140 and a miscella 130. Method 700 also includes removing
miscella 130 from the extracted substrate 140.
[0428] According to depicted exemplary method 700, extracted
substrate 140 is subjected to a sulfite process 702. Sulfite
process 702 dissolves lignin. Depicted exemplary method 700,
continues with enzymatic hydrolysis 704 of extracted substrate 140.
In other exemplary embodiments of the invention, other types of
hydrolysis are employee (e.g. using a mineral acid and/or reactive
fluid). Hydrolysis 704 produces a hydrolysate 706. In some
exemplary embodiments of the invention, extractant 110 includes a
weak acid as described hereinabove. In some embodiments, the weak
acid includes sulfurous acid. In some exemplary embodiments of the
invention, the sulfurous acid is formed by adding SO.sub.2 to a
mixture of solvent and water. Optionally, the concentrations of
weak acid are as described hereinabove.
[0429] Alternatively or additionally, in some exemplary
embodiments, a predetermined-pressure-temperature-time profile is
applied to substrate 100 prior to extracting 120 as described
hereinabove.
Exemplary Recycling Considerations
[0430] In some exemplary embodiments of the invention, method 101
(FIG. 1) includes separating solvent and/or weak acid from miscella
130 to form a recycling stream (155 and/or 111) including solvent
and/or weak acid. In some embodiments, the separating of the
solvent includes evaporation 150 and/or and extraction into another
solvent. In the depicted embodiment, the solvent is separated by
evaporation 150, optionally in an evaporation module. In some
embodiments, the weak acid is sulfurous acid and excess of SO.sub.2
is evaporated from miscella 130. According to various exemplary
embodiments of the invention the method includes separating at
least a portion of the water-soluble organic solvent and/or the
weak acid from miscella 130 and/or 240.
[0431] In some exemplary embodiments of the invention, evaporation
150 is conducted to further separate the recycled solvent 155
and/or weak acid and to form an acid-rich fraction (SO.sub.2 rich
vapor fraction) and an acid-depleted fraction. Optionally, the
acid-depleted vapor phase is condensed to form a weak acid-depleted
liquid phase and the acid-rich vapor phase is condensed to form a
weak acid-rich liquid phase. Optionally, recycled solvent 155 is
combined with recycled extractant 111 as indicated by dashed
arrows.
[0432] In some exemplary embodiments of the invention, (FIG. 2) the
weak acid-depleted liquid phase 110A and/or the acid-rich vapor
fraction 110B collectively designated in FIG. 1 as extractant 110
are separately modified and separately recycled via module 210 to
extracting 120.
[0433] In some exemplary embodiments of the invention, miscella 130
includes water (in aqueous phase 160) and a lipophilic fraction
170. Optionally, lipophilic fraction 170 is gradually separated
(e.g. by stepwise distillation) from miscella 130 to form an
aqueous phase 160 and a lipophilic fraction 170 for example by
gradual evaporation of solvent, weak acid and volatile organic
compounds. As used in this specification and the accompanying
claims the terms "distill" and "distillation" include all methods
of separation based upon differential evaporation. Optionally, the
separating of the water-soluble organic solvent and the weak acid
from miscella 130 forms an aqueous phase 160. In some embodiments,
water and water-soluble impurities in aqueous phase 160 are
modified and recycled in optional aqueous phase treatment 165.
[0434] In some exemplary embodiments of the invention, aqueous
phase 160 includes a substantial quantity of carbohydrates and
aqueous phase treatment 165 comprises anaerobic treatment of
aqueous phase 160 to produce methane. In some embodiments, this
methane is used as an energy source in the process (e.g. combusted
to heat a still or to provide steam for steam explosion).
[0435] In some embodiments of the invention, evaporation 150
includes distilling of miscella 130 to produce a solvent phase
(depicted as arrow 155), aqueous phase 160 and lipophilic fraction
170. In some embodiments, the solvent phase includes distillation
overheads. In some embodiments, aqueous phase 160 and/or lipophilic
fraction 170 remain in the bottom phase. In some embodiments,
aqueous phase 160 and lipophilic fraction 170 are separated for
example by decantation, cyclone separators or centrifuges. In some
embodiments, separation of lipophilic material 190 is conducted at
an elevated temperature. The elevated temperature may be important
if the lipophilic material has a high melting point. In some
embodiments, separated aqueous phase 160 is biologically
(optionally anaerobically) digested. According to various exemplary
embodiments of the invention the COD (Chemical Oxygen Demand) of
separated aqueous phase 160 is in the range of 5,000 to 100,000
PPM, optionally 10,000 to 80,000 PPM, optionally 15,000 to 70,000
PPM, optionally 20,000-50,000 PPM. In some exemplary embodiments of
the invention, the sulfite/sulfate content of aqueous phase 160 to
be treated is kept below 10,000 PPM, optionally below 8,000 PPM,
optionally below 6,000 PPM, optionally below 4000 PPM, optionally
below 2000 PPM. In some embodiments, aqueous phase 160 is treated
with lime before biological digestion to remove sulfur as
precipitated CaSO3/CaSO4.
[0436] In some embodiments, method 101 includes lipophilic fraction
treatment 180 of lipophilic fraction 170. In some exemplary
embodiments, the solvent phase comprises the water-soluble organic
solvent 200 and at least a portion of the weak acid. In some
embodiments, treatment 180 includes additional fractionation of
lipophilic fraction 170 to separated lipophilics 190 and separated
solvent 200.
[0437] In some exemplary embodiments, aqueous phase 160 comprises
less than 10%, 8%, 5%, 3% or 1% carbohydrates or lesser or
intermediate amounts.
[0438] In some embodiments, liphophilic phase 170 is desolventized,
optionally using steam from steam explosion 103.
[0439] In some embodiments, method 101 includes periodic harvest of
a separated lipophilic fraction 170 separated from miscella 130
during distillation of water-soluble organic solvent and the weak
acid by evaporating 150. In those embodiments of the invention
which employ steam explosion, the released steam can optionally be
used as a source of heat energy for evaporating 150, which
optionally takes the form of distillation.
[0440] In some exemplary embodiments of the invention, lipophilic
fraction treatment 180 includes fractionation of lipophilic
fraction 170. In some embodiments, fractionation is by step-wise
solvent removal.
[0441] Alternatively or additionally, lipophilic fraction treatment
180 includes further evaporating SO.sub.2 and solvent together to
form a vapor mixture. Optionally, the vapor mixture is condensed to
form separated solvent solution 200 which includes solvent and
SO.sub.2 (optionally as H.sub.2SO.sub.3). Optionally, solution 200
is recycled to extracting 120. In some embodiments, separated
solvent 200 to be recycled is modified by modification module
210.
[0442] Optionally, the weak acid is not fully separated. Part of
the weak acid may form (water-soluble) salts that remain in the
miscella. For example, when sulfurous/SO.sub.2 is used, it can
oxidize partially into sulfuric/SO.sub.3, which is more difficult
to separate. Optionally, air is removed from substrate 100 prior to
extracting 120, e.g. by steaming. In some exemplary embodiments of
the invention, this steaming contributes to a reduction in contact
between air and extractant 110 during extracting 120.
[0443] In some exemplary embodiments of the invention, modification
includes removal of a fraction of, ioptionall substantially all of,
VOCs from the solvent, e.g. by distillation. According to various
exemplary embodiments of the invention recycled extractant 111 is
used as extractant 110 in a subsequent round of extracting,
optionally in combination with recycled solvent 155.
Exemplary Solvent Recycling
[0444] Referring again to FIG. 1: In some exemplary embodiments of
the invention, water-soluble solvent in extractant 110 is at least
partially recycled from a previous extraction and/or a previous
extraction stage (e.g. 155 and/or 111 in FIG. 1). In some
embodiments, recycling involves distillation from a miscella (e.g.
130 and/or 240). Typically, distillation leaves some water in the
solvent. Condensation of vapors from the distillation column forms
a mixture of water and solvent. For example, if acetone is used as
the solvent, condensation can form a mixture of acetone:water at
ratio of about 90:10. Extractant 110 can then be prepared by adding
SO.sub.2 to this acetone/water mixture.
[0445] In some embodiments, solvent phase 155 includes
water-soluble organic solvent and at least a portion of the weak
acid provided in the extractant. As indicated in FIG. 1, recovered
solvent 155 is optionally re-used as part of extractant 110 in
extracting 120.
[0446] According to various exemplary embodiments of the invention
the recycled extractant contains about 70% to 95% solvent and 30%
to 5% water. In some embodiments, the recycled extractant contains
about 90% solvent and about 10% water. According to these
embodiments, extracting 120 is with an extractant comprising
solvent and water.
[0447] In some embodiments, the solvent/substrate ratio is selected
so that the water content of the extractant increases to about 20%,
optionally to about 30%, optionally to about 40%, optionally to
about 50%, optionally to about 60% or even to about, to about 70%
or more due to water transfer from the substrate.
[0448] During subsequent extraction 120, extractant 110 picks up
water from substrate 100. If substrate 100 is wood, such as pine
wood, it typically includes slightly more than 50% water at the
beginning of extraction 120 and exits as extracted substrate 140
with about 10% water. At the same time, miscella 130 carries a
correspondingly larger amount of water than extractant 110.
[0449] In some exemplary embodiments of the invention, miscella 130
contains about 45% water. According to various exemplary
embodiments of the invention, this percentage may vary with one or
more of the water content of substrate 100 (or disrupted substrate
105) and/or the amount of water in extractant 110 and/or the ratio
of extractant to substrate applied during extracting 120.
[0450] In some exemplary embodiments of the invention, solvent is
first distilled from miscella 130 and the vapors are condensed to
reform a solvent-water mixture. In many cases the weak acid is
extracted with the solvent and is condensed with it to reform
extractant 110. In some embodiments, reconstitution of extractant
110 includes some acid makeup (i.e. addition of fresh acid).
[0451] As the concentration of the solvent in the miscella
deceases, lipophilic material(s) can precipitate out. In some
cases, this precipitated lipophilic material may still contain some
solvent. Optionally, another distillation (lipophilic fraction
treatment 180) separates residual solvent 200.
[0452] Optionally, steam formed on depressurizing the steam
explosion (thermo-mechanical treatment 103) can be used for
distillation (e.g. 180) of lipophilic fraction 170. Optionally,
distilling the solvent from the miscella is divided into several
steps. This results in division of the lipophilic fraction 170 into
several fractions. Optionally, this division contributes to an
increase in total value.
Exemplary Extraction Effects
[0453] In some exemplary embodiments of the invention,
lignocellulosic substrate 100 includes water. Optionally,
extracting 120 transfers water from substrate 100 to extractant
110.
[0454] According to various exemplary embodiments of the invention
the initial water content of lignocellulosic substrate 100 is in
the range of from about 10% to about 90% wt, optionally from about
20% to about 80% wt, from about 30% to about 70% wt, or from about
40% to about 60% wt.
[0455] According to various exemplary embodiments of the invention
the water content of extracted substrate 140 is optionally in the
range of from about 1% to about 40% wt, from about 2% to about 30%
wt, from about 5% to about 25% wt, or from about 10% to about 20%
wt. According to various exemplary embodiments of the invention
extraction 120 lowers the water content of the substrate from about
50% to about 25%, about 50% to about 20%, about 50% to about 18%,
about 50% to about 16%, or intermediate or lower percentages.
Alternatively or additionally, according to various exemplary
embodiments of the invention extraction 120 lowers the water
content of extracted substrate 140 to less than about 25%,
optionally less than 20%, and optionally less than about 18% of the
water provided in lignocellulosic substrate 100.
[0456] In some exemplary embodiments of the invention,
thermo-mechanical treatment 103 contributes to an increase in the
difference in water content between substrate 100 and extracted
substrate 140. According to various embodiments of the invention,
the initial water content of extractant 110 is in the range of from
about 1% to about 30% wt, or about 2% to about 20% wt, or about 5%
to about 15% wt, or about 8% to about 12% wt. Alternatively or
additionally, a, the water content of the extractant after
extraction is in the range of from about 20% to about 80% wt, or
from about 30% to about 70% wt, or from about 40% to about 60%
wt.
[0457] In some embodiments, water content in miscella 130 is
greater than water content of extractant 110 by at least 10%, at
least 20%, at least 30% or more. This difference comes in large
part from water extracted from the substrate. In some exemplary
embodiments of the invention, at least 50% of water originally
present in substrate 100 is removed and transferred to miscella 130
and/or additional miscella 240. In some embodiments, water content
of extracted substrate 140 is less than 20% wt, less than 15% wt,
or less than 8% wt.
[0458] In some embodiments of the invention, 50%, 65% or even, 75%
or more of the ash content of substrate 110 is extracted to
miscella 130. In some substrates 100 calcium and magnesium form a
large fraction of the cation content of the ash. In some exemplary
embodiments of the invention, at least 50%, at least 60%, or even
75% or more of the magnesium and/or calcium contents of substrate
100 is extracted to miscella 130. These levels of ash extraction
from substrate 100 are significantly more efficient than previously
available alternatives.
[0459] In some exemplary embodiments of the invention, extracted
substrate 140 contains less than 50% of the calcium and magnesium
content provided in substrate 110. In some exemplary embodiments of
the invention, extracted substrate 140 contains less than 80%, less
than 70%, less than 60%, or less than 50% of the lipophilic
fraction material originally present in substrate 100. These levels
of lipophilic fraction removal from substrate 100 are significantly
more efficient than previously available alternatives.
[0460] In other words, at least 20%, at least 30%, at least 40%, at
least 50%, at least 60%, at least 70%, at least 80% or at least 90%
of the lipophilic fraction material of originally present in
substrate 100, as determined by DCM extraction, migrates to
miscella 130.
[0461] Alternatively or additionally, extracted substrate 140
contains less than 60%, 50%, 40%, or 30% of the pectin provided in
lignocellulosic substrate 100.
[0462] Alternatively or additionally, the total amount of material
extracted during contacting (extracting 120) is 0.5-10%, 1% to 9%,
2% to 8%, or 3% to 7% calculated based on the dry weight of
substrate 100.
[0463] Alternatively or additionally, a carbohydrate content of
miscella 130 is less than 10%, less than 8%, less than 4%, or less
than 2% of the carbohydrates in substrate 100.
Exemplary Hydrolysis Considerations
[0464] In some exemplary embodiments of the invention, dried
extracted substrate 230 is hydrolyzed 250. In some embodiments,
hydrolyzing 250 is accomplished by contacting with an aqueous
hydrolysis medium with a weight ratio of HCl to (HCl+water) of 30%,
35%, 37%, 40%, 42%, 45% or intermediate or greater percentages.
[0465] In some embodiments of the invention, hydrolysis is improved
by the extraction described above. Optionally, the improvement can
be in hydrolysis rate and/or in one or more hydrolyzate parameters.
Hydrolyzate parameters include, but are not limited to, sugar
composition and/or concentration of substrate derived impurities
and/or concentration of degradation products of sugars.
[0466] Hydrolysis 250 produces hydrolyzate 270 including HCl and at
least one carbohydrate as well as a residual lignin stream 260
which includes lignin, HCl and water. Typically, streams 260 and
270 are separated and each is subjected to appropriate downstream
processing.
[0467] Hydrolyzate 270 is processed to remove acid and/or increase
sugar content and/or modify sugar composition. Downstream
processing of hydrolyzate 270 may be, for example, according to
methods disclosed in co-pending provisional patent application U.S.
61/500,169.
[0468] Lignin stream 260 is processed to remove acid and/or
deacidify the lignin and/or dry the lignin and/or recover residual
sugars. Downstream processing of lignin 260 may be, for example,
according to methods disclosed in co-pending provisional patent
application U.S. 61/491,243 which is fully incorporated herein by
reference.
[0469] In some exemplary embodiments of the invention, hydrolyzate
270 contains 2%, 1%, or even 0.5% or less solids. Practice of
extraction methods as described hereinabove optionally contributes
to a reduction in this solids percentage.
Exemplary Interactions Between Substrate and Practice of Exemplary
Methods
[0470] According to various embodiments of the invention any
lignocellulosic material can serve as substrate 100. In some
exemplary embodiments of the invention, substrate 100 includes one
or more of wood, sugarcane bagasse, agricultural residues, oil palm
biomass, energy crops and recycled biomass. In some embodiments
substrate 100 is provided as wood chips, for example chips with a
largest measurement of 4 inches, 3 inches, 2 inches, 1.5 inches or
1 inch or intermediate or smaller measurements. In some embodiments
of the invention, a soft wood, such as pine, is used as substrate
100.
[0471] Typically, substrate 100 includes at least 10%, 20% or even
30% or more water. In some exemplary embodiments of the invention,
substrate 100 is not dried prior to extracting 120 or is slightly
dried to a water level in the range of 40% to 50%. This slight
drying may be accomplished, for example, by harvesting the
substrate and allowing it to stand prior to using it as substrate
100. In some embodiments, standing continues for 5, 10, 15, 20, 30
or 40 or an intermediate or greater number of days. In some
embodiments of the invention, wood serves as a substrate and stands
for at least 5 days prior to use. Alternatively or additionally,
the substrate is processed to increase surface area prior to
standing. Optionally, the substrate is wood and an increase in
surface is achieved by splitting logs and/or chipping the wood. In
some exemplary embodiments of the invention, increasing surface
area contributes to an increase in drying speed and/or a reduction
in volatile organic compounds and/or resins present in the
substrate.
Exemplary Impurities and Associated Problems
[0472] Substrate 100 has been described as containing impurities
which include ash and a lipophilic fraction. The term "ash" refers
to those materials which remain after complete combustion of the
substrate as accepted in the art.
[0473] The lipophilic fraction includes non-lignin, non-cellulosic,
non-ash material such as resins, pitch, tall oils, terpenes (and
other volatile organic compounds) and proteinaceous materials.
Measurement of the lipophilic fraction in a substrate is most often
conducted by extraction.
[0474] In the food industry, Soxhlet extraction with ether is
typically employed and the "lipophilic fraction" of a food is
referred to as an "ether extract". This well known procedure is
described in, for example, in "Experimental organic chemistry:
Principles and Practice" (1996) by Harwood and Moody; Blackwell
Scientific Publications, Oxford England. In the paper pulp industry
extraction in Dichloromethane (DCM) is more common and the
"lipophilic fraction" of wood is referred to as "DCM extractives"
(ASTM D3971-89 (2010)). Determination of Ethanol extractives is
also known (ASTM E1690-08).
[0475] The term "lipophilic fraction" as used in this specification
and the accompanying claims refers to fatty acids and/or resin
acids and/or triglycerides as well as any organic material less
than 1% soluble in water at 25.degree. C.
[0476] The lipophilic fraction may include materials that are not
typically found in DCM extractives (as determined by conventional
procedures), such as intermediate process products formed in steps
preceding the extraction, or in the extraction in the presence of
the weak acid.
[0477] In some embodiments, the lipophilic fraction includes at
least 70%, 80%, 90%, or 100% of the DCM extractives present in the
substrate prior to extraction. Alternatively or additionally, the
lipophilic fraction may include less than 30%, 20%, 10%, 5% or
substantially 0% of materials which do not belong to the DCM
extractives.
[0478] Using this specification as a guide, it will be possible for
a skilled practitioner to characterize the lipophilic fraction of a
candidate substrate 100 using available data and/or standard
analytic procedures, and adjust method 101 based upon the specific
lipophilic fraction profile of the candidate substrate. According
to various exemplary embodiments of the invention such adjustment
can involve altering the solvent and/or weak acid employed and/or
their amounts.
[0479] In general, the lipophilic fraction and/or ash in
lignocellulosic substrate may not be evenly distributed. For
example, in pinewood, large differences are found in extractives in
the radial direction in wood stems. Pines have many more resin
acids in the heartwood than in the sapwood. Heartwood also contains
fewer triglycerides and more free fatty acids than the sapwood.
Many extractives are incorporated deep within the cell structures
and therefore may not be easily accessed and removed by the solvent
during pretreatment. For these reasons, thermo-mechanical treatment
103 may contribute to extraction efficiency.
[0480] The ash fraction of substrate 100 can include inorganic
cations, inorganic anions or both. Common cations present in
substrate 100 include, but are not limited to, calcium, magnesium,
potassium and sodium. In many cases, substrate 100 includes both
calcium and magnesium and separation of these cations from the
substrate may be considered a technical problem to be overcome.
[0481] Presence of ash and/or lipophilic fraction in hydrolyzate
270 and/or lignin stream 260 can cause undesirable processing
complications. These complications may be associated with, for
example, solvent extraction used for separation of HCl from sugars
and/or lignin.
[0482] Components of the lipophilic fraction tend to accumulate in
solvent used to remove HCl. Since this solvent is costly, it is
often recycled. If the lipophilic fraction components are not
removed, recycling is not industrially feasible. Removal of
lipophilic fraction from this solvent requires costly treatment
which detracts from the industrial feasibility. Alternatively or
additionally, anions present in the ash can be converted to their
acid form upon contact with HCl and complicate use of solvent
extraction for HCl recovery. Alternatively or additionally, ash can
cause difficulties for other methods of HCl separation from
carbohydrates in the hydrolyzate, such as chromatographic methods.
Alternatively or additionally, lipophilic fraction components can
interfere with hydrolysis 250 by fouling filters and/or causing
"clumping" of partially hydrolyzed wood and/or of lignin. In
addition, the lipophilic fraction and/or ash tend to contaminate
lignin and lower its value.
Exemplary Cost Considerations
[0483] Some exemplary embodiments of the invention contribute to a
reduction in downstream processing costs of hydrolyzate 270 and/or
lignin stream 260 and/or hydrolysis 250. Optionally, this
contribution can be a deciding factor in whether hydrolysis 250 is
economically feasible. Alternatively or additionally, this
contribution can change a particular substrate from a "poor
candidate" for acid hydrolysis into a "good candidate" for acid
hydrolysis.
[0484] For example, removal of ash and/or lipophilic impurities
from substrate 100 according to an exemplary method of the
invention lowers the cost of energy and reagents required for the
formation of hydrolyzate 270, for separation of the acid and for
carbohydrates purification from the hydrolyzate and/or for the
treatment of the lignin. Thus, according to an embodiment, at least
one of the energy cost and the reagents cost for treating
hydrolyzate 270 and/or treating the lignin formed from said
separated extracted feed is lower by at least 2%, at least 3%, at
least 5%, or at least 10% compared with that of treating
hydrolyzate formed from said lignocellulosic substrate.
Exemplary Optional Alkaline Treatment
[0485] FIG. 5 is a simplified flow diagram of a method according to
some exemplary embodiments of the invention indicated generally as
501.
[0486] Depicted exemplary method 501 includes contacting 510 of a
substrate 500 with an alkali extractant 505 to form a lipophilic
fraction depleted extracted feed 520 and a solution comprising an
alkali salt of fatty acids (alkali solution 530). According to
various embodiments of the invention substrate 500 includes
substrate 100 and/or extracted substrate 140 (FIG. 1). According to
various exemplary embodiments of the invention extractant 505
comprises an alkali, optionally in combination with a water-soluble
organic solvent.
[0487] According to some embodiments said water-soluble organic
solvent includes, but is not limited to, ketones, aldehydes, esters
and alcohols with up to four carbon atoms. In some embodiments, the
solvent of extractant 505 is a mixture of several organic
water-soluble organic solvents. In some embodiments, extractant 505
includes acetone. In some embodiments, acetone is the sole solvent
in extractant 505.
Exemplary Profile Considerations
[0488] Referring again to FIG. 1: in those exemplary embodiments of
the invention which involve application of a predetermined
pressure-temperature-time profile (103) to substrate 100,
predetermination of profile parameters can be based, for example,
upon analysis of a degree of disruption of the substrate. One way
to evaluate a degree of disruption of the substrate is to estimate
the proportion of structural disruption occurring as a result of
the treatment. Optionally, this estimation is done using
microscopy, optionally electron microscopy. According to various
exemplary embodiments of the invention disruption of cells and/or
multicellular structures (e.g. water transporting vessels) can be
evaluated.
[0489] In some embodiments, predetermination of profile parameters
is based upon calculation of a severity factor which predicts the
extent of the chemical degradation of the substrate. The "severity
factor" of the profile is defined as:
log ( R ) = log ( t * exp ( T - 100 14.75 ) ) ##EQU00001##
[0490] Thus, a slight increase in temperature causes a large
increase in "R" because of the exponential dependency. However,
different lignocellulosic substrates respond differently to
treatment with high pressure steam so that this formula is
informative only with regard to changes in profile for a same
substrate. In some embodiments, the predetermined
pressure-temperature-time profile is characterized by severity
factor of at least 3, 3.2, 3.4, 3.6, 3.8, or at least 4.0.
Alternatively or additionally, in some embodiments, the
predetermined pressure-temperature-time profile is characterized by
severity factor of less than 5, 4.8, 4.6, 4.4, or even less than
4.2.
[0491] In some embodiments, the predetermined
pressure-temperature-time profile is characterized by severity
factor in the range of 3.4 to 4.2; the range of 3.6 to 4.0. In some
embodiments, the severity factor is about 3.8. In some exemplary
embodiments of the invention, the predetermined
pressure-temperature-time profile is selected so that at least 10%,
optionally at least 20%, optionally at least 30%, optionally at
least 40% of cells or intermediate or greater proportions of cells
are disrupted. In some embodiments, the predetermined
pressure-temperature-time is selected so that at least 10%, at
least 20%, at least 30%, at least 40% of multicellular structures
or intermediate or greater proportions of multicellular structures
are disrupted. According to various embodiments of the invention
temperatures applied in the predetermined pressure-temperature-time
profile can be greater than 150.degree., 160.degree., 170.degree.,
180.degree., 190.degree. C. or intermediate or higher temperatures.
In some embodiments, temperatures applied in the predetermined
pressure-temperature-time profile can be less than 250.degree.,
less than 240.degree., less than 230.degree., less than
220.degree., less than 210.degree. C. or intermediate or lower
temperatures. According to various embodiments of the invention
temperatures applied in the predetermined pressure-temperature-time
profile can be in the range of 150.degree. to 250.degree. C.,
160.degree. to 240.degree. C., 170.degree. C. to 230.degree. C.,
180.degree. to 220.degree. C., 190.degree. to 210.degree. C., or
intermediate ranges. According to various embodiments of the
invention the time for which the predetermined
pressure-temperature-time profile is applied can be greater than
0.1, greater than 0.2, greater than 0.3, greater 0.4 minutes or
intermediate or greater times. In some embodiments, the time for
which the predetermined pressure-temperature-time profile is
applied is less than 10, less than 6, less than 3, less than 2
minutes, or intermediate or lesser times. According to various
exemplary embodiments of the invention the time for which the
predetermined pressure-temperature-time profile is applied is in
the range of 0.1 to 10.0, 0.2 to 6.0, 0.3 to 3.0 or 0.4 to 2.0,
minutes or intermediate ranges. In some embodiments, the pressure
applied during the predetermined pressure-temperature-time profile
is at least 6, at least 8, at least 10, at least 12, at least 14,
at least 15, at least 16 bar or intermediate or greater pressures.
Optionally, quantitative analysis of an achieved degree of
disruption from an initial applied profile on a given substrate can
lead to a conclusion the profile is "too strong" or "not strong
enough". The formula given above provides a rationale for how to
adjust the profile to be "stronger" or "less strong" and allows the
practitioner to evaluate in advance what magnitude of adjustment
may be appropriate.
Exemplary Hydrolysis Considerations
[0492] Referring again to FIG. 1: according to various embodiments
of the invention an extractant 110 including a weak acid is
employed at extracting 120. In some exemplary embodiments of the
invention, control is exercised over an amount of hydrolysis of
cellulose and/or hemicellulose resulting from contact of this weak
acid with the substrate. In some embodiments, the weak acid in
extractant 110 hydrolyzes less than less than 10%, less than 8%,
less than 5%, less than 3%, less than 1%, less than 0.5% or
intermediate or lesser percentages, of cellulose in the substrate
during extracting 120 before miscella 130 is removed.
[0493] Alternatively or additionally, in some embodiments, the weak
acid in extractant 110 hydrolyzes less than less than 10%, less
than 8%, less than 5%, less than 3%, less than 1%, less than 0.5%,
or intermediate or lesser percentages of hemicellulose in the
substrate during extracting 120 before miscella 130 is removed.
Exemplary Filtration Considerations
[0494] FIG. 8 is a simplified flow diagram of a method according to
another exemplary embodiment of the invention depicted generally as
800. Depicted exemplary method 800 includes extracting 120
lignocellulosic substrate 100 with an extractant 110 comprising a
water-soluble organic solvent to form an extracted substrate
140.
[0495] According to depicted exemplary method 800, extracted
substrate 140 is hydrolyzed 250 to form hydrolyzate 260 (See FIG.
1) and a residual lignin stream 270. Residual lignin stream 270
includes solid lignin, depicted here as 806. According to exemplary
method 800, hydrolyzate 260 is separated by filtration 802, to
obtain separated hydrolyzate 804 and separated solid lignin 806.
Following filtration 802, separated hydrolyzate 804 contains less
than 2, less than 1, less than 0.5, or less than 0.1% solids. In
some embodiments of method 800 extraction 120 contributes to an
increase in filtration rate relative to a filtration rate obtained
by hydrolyzing substrate 100 without extracting 120, using an
identical filter and identical filtration conditions. Optionally,
the filtration rate is faster by at least 10%, by at least 25%, by
at least 40%, by at least 50%, or intermediate or greater
percentages. In some embodiments, each of separated hydrolyzate 804
and solid lignin 806 is subjected to appropriate downstream
processing. Alternatively or additionally, in some exemplary
embodiments, a predetermined-pressure-temperature-time profile is
applied to substrate 100 prior to extracting 120 as described
hereinabove in the context of FIG. 1.
[0496] In some embodiments, a substrate of the invention is pine
wood chips. The pine wood chips are subjected to a
thermo-mechanical treatment of steam explosion (e.g. with a
severity factor of about 3.8). The broken down wood chips are then
subjected to extracting by an extractant acetone, 0.005% to 0.01%
acetic acid, and water. Miscellae or a miscelle layer which
includes the extractant and various impurities from the pine wood
is removed. The extractant from the miscelle is regenerated using
any method described herein. The extracted substrate which is
primarily cellulose, hemicelluloses and lignin is dried and
subsequently hydrolyzed. Hydrolysis can occur, e.g., in 42%
HCl(HCL+water) to produce a hydrolyzate stream and lignin stream.
The hydrolyzate comprises sugars which are used to make commercial
products as varied as xylose and industrial polymers and enzymes
made by growing organisms using the sugars. The lignin stream is
also used to make commercial products.
Exemplary Downstream Processing
[0497] FIG. 6a is a simplified flow diagram of a method according
to another exemplary embodiment of the invention depicted generally
as 600. Depicted exemplary method 600 includes providing 610 a
hydrolyzate (e.g. 270) containing soluble sugars as described above
and converting 620 at least a portion of the sugars to a conversion
product 630.
[0498] FIG. 6b is a simplified flow diagram of a method according
to another exemplary embodiment of the invention depicted generally
as 601. Depicted exemplary method 601 includes providing 611 an
extracted substrate (e.g. 140 or 230) as described above and
converting 620 at least a portion of the sugars to a conversion
product 630.
[0499] According to various exemplary embodiments of the invention,
conversion 620 includes at least one of fermentation (aerobic
and/or anaerobic fermentation), a thermal process involving
exposure to temperatures in excess of 200.degree. C., chemical
conversion, enzymatic conversion, electrolytic reduction, catalytic
hydrogenation, and isomerization.
[0500] For embodiments comprising fermentation, the fermentation
process may employ a genetically modified organism (GMO). A wide
range of GMOs are potentially compatible with sugars produced by
the methods described herein. GMOs may include, but are not limited
to, members of the genera Clostridium, Escherichia, Salmonella,
Zymomonas, Rhodococcus, Pseudomonas, Bacillus, Enterococcus,
Alcaligenes, Lactobacillus, Klebsiella, Paenibacillus,
Corynebacterium, Brevibacterium, Pichia, Candida, Hansenula and
Saccharomyces. Hosts that may be particularly of interest include:
Oligotrophacarboxidovorans, Escherichia coli, Bacillus
licheniformis, Paenibacillusmacerans, Rhodococcuserythropolis,
Pseudomonas putida, Lactobacillus plantarum, Enterococcus faecium,
Enterococcus gallinarium, Enterococcus faecalis, Bacillus subtilis
and Saccharomyces cerevisiae. Also, any of the known strains of
these species may be utilized as a starting microorganism. In
various exemplary embodiments, the microorganism is an actinomycete
selected from Streptomyces coelicolor, Streptomyces lividans,
Streptomyces hygroscopicus, or Saccharopolysporaerytlzraea. In
various exemplary embodiments, the microorganism is aneubacterium
selected from Escherichia coli, Pseudomonas flucrescens,
Pseudomonas putida, Pseudomonas aeruginosa, Bacillus subtilis, or
Bacillus cereus.
[0501] In some exemplary embodiments, the GMO is a gram-negative
bacterium. In some exemplary embodiments, the recombinant
microorganism is selected from the genera Zymomonas, Escherichia,
Alcaligenes, and Klebsiella. In some exemplary embodiments, the
recombinant microorganism is selected from the species Escherichia
coli, Cupriavidus necator, and Oligotropha carboxidovorans. In some
exemplary embodiments, the recombinant microorganism is an E. coli
strain.
[0502] In some exemplary embodiments of the invention, conversion
product 630 may comprise lactic acid. The potential of lactic acid
as a commodity chemical, for example for use in the production of
various industrial polymers, is known and has been described in for
example, U.S. Pat. Nos. 5,142,023; 5,247,058; 5,258,488; 5,357,035;
5,338,822; 5,446,123; 5,539,081; 5,525,706; 5,475,080; 5,359,026;
5,484,881; 5,585,191; 5,536,807; 5,247,059; 5,274,073; 5,510,526;
and 5,594,095. (The complete disclosures of these seventeen
patents, are incorporated herein by reference.)
[0503] Various exemplary embodiments of conversion processes 620
including fermentation and/or chemical processes which are
described in U.S. Pat. No. 7,629,010; U.S. Pat. No. 6,833,149; U.S.
Pat. No. 6,610,867;U.S. Pat. No. 6,452,051; U.S. Pat. No.
6,229,046; U.S. Pat. No. 6,207,209; U.S. Pat. No. 5,959,128; U.S.
Pat. No. 5,859,270; U.S. Pat. No. 5,847,238; U.S. Pat. No.
5,602,286; and U.S. Pat. No. 5,357,035, the contents of which are
incorporated herein by reference for all purposes. According to
various exemplary embodiments of the invention sugars present the
hydrolyzate provided at 610 are incorporated into a fermentation
product as described in the following US Patents, the contents of
each of which are hereby incorporated by reference: U.S. Pat. No.
7,678,768; U.S. Pat. No. 7,534,597; U.S. Pat. No. 7,186,856; U.S.
Pat. No. 7,144,977; U.S. Pat. No. 7,019,170; U.S. Pat. No.
6,693,188; U.S. Pat. No. 6,534,679; U.S. Pat. No. 6,452,051; U.S.
Pat. No. 6,361,990; U.S. Pat. No. 6,320,077; U.S. Pat. No.
6,229,046; U.S. Pat. No. 6,187,951; U.S. Pat. No. 6,160,173; U.S.
Pat. No. 6,087,532; U.S. Pat. No. 5,892,109; U.S. Pat. No.
5,780,678; and U.S. Pat. No. 5,510,526, the contents of which are
incorporated herein by reference for all purposes. Alternatively or
additionally, conversion product 630 can be, for example, an
alcohol, carboxylic acid, amino acid, methane, or monomer for the
polymer industry or a protein. According to various exemplary
embodiments of the invention the protein can be provided in the
form of one or more enzymes, feed proteins, food proteins and
protein-rich microorganisms ("single-cell proteins").
[0504] In some exemplary embodiments of the invention, conversion
product 630 is a final product which is used "as is" as a consumer
product. In other exemplary embodiments of the invention,
conversion product 630 serves as an ingredient in a final product
which is used by an industry and/or by individuals. In other
embodiments of the invention, conversion product 630 is subject to
one or more additional rounds of conversion (not depicted) to
produce a consumer product. According to various embodiments of the
invention a consumer product may be selected from the group
consisting of a detergent, a polyethylene-based product, a
polypropylene-based product, a polyolefin-based product, a
polylactic acid (polylactide)-based product, a
polyhydroxyalkanoate-based product and a polyacrylic-based product.
Optionally, the detergent includes a sugar-based surfactant, a
fatty acid-based surfactant, a fatty alcohol-based surfactant, or a
cell-culture derived enzyme.
[0505] Optionally, the polyacrylic-based product is a plastic, a
floor polish, a carpet, a paint, a coating, an adhesive, a
dispersion, a flocculant, an elastomer, an acrylic glass, an
absorbent article, an incontinence pad, a sanitary napkins, a
feminine hygiene product, and a diaper.
[0506] Optionally, the polyolefin-based product is a milk jug, a
detergent bottle, a margarine tub, a garbage container, a plumbing
pipe, an absorbent article, a diaper, anon woven, an HDPE toys or
an HDPE detergent packaging.
[0507] Optionally, the polypropylene based product is an absorbent
article, a diaper or a non woven. Optionally, the polylactic acid
based product is a packaging of an agriculture product or of a
dairy product, a plastic bottle, a biodegradable product or a
disposable.
[0508] Optionally, the polyhydroxyalkanoate based product is
packaging of an agriculture product, a plastic bottle, a coated
paper, a molded or extruded article, a feminine hygiene product, a
tampon applicators, an absorbent article, a disposable nonwoven or
wipe, a medical surgical garment, an adhesive, an elastomer, a
film, a coating, an aqueous dispersant, a fiber, an intermediate of
a pharmaceutical or a binder.
[0509] Optionally, conversion product 630 is ethanol, butanol,
isobutanol, a fatty acid, a fatty acid ester, a fatty alcohol or
biodiesel.
[0510] In some embodiments of the invention, method 700 includes
processing of conversion product 630 to produce at least one
product such as, for example, an isobutene condensation product,
jet fuel, gasoline, gasohol, diesel fuel, drop-in fuel, diesel fuel
additive, or a precursor thereof. Optionally, the gasahol is
ethanol-enriched gasoline and/or butanol-enriched gasoline.
[0511] In some embodiments of the invention, the product produced
from conversion product 630 is diesel fuel, gasoline, jet fuel or a
drop-in fuel. Various exemplary embodiments of the invention
include consumer products, precursors of consumer product, and
ingredients of consumer products produced from conversion product
630.
[0512] Optionally, the consumer product, precursor of a consumer
product, or ingredient of a consumer product includes at least one
conversion product 630 such as, for example, a carboxylic or fatty
acid, a dicarboxylic acids, a hydroxylcarboxylic acids, a hydroxyl
di-carboxylic acid, a hydroxyl-fatty acid, methylglyoxal, mono-,
di-, or poly-alcohol, an alkane, an alkene, an aromatic, an
aldehyde, a ketone, an ester, a biopolymer, a protein, a peptide,
an amino acid, a vitamin, an antibiotics, and a pharmaceutical. For
example, the product may be ethanol-enriched gasoline, jet fuel, or
biodiesel.
[0513] Optionally, the consumer product has a ratio of carbon-14 to
carbon-12 of about 2.0.times.10.sup.-13 or greater.
[0514] According to various embodiments of the invention, the
consumer product includes an ingredient of a consumer product as
described above and an additional ingredient produced from a raw
material other than lignocellulosic material. In some exemplary
embodiments of the invention, the ingredient and the additional
ingredient produced from a raw material other than lignocellulosic
material are essentially of the same chemical composition.
[0515] In some embodiments, the consumer product includes a marker
molecule at a concentration of at least 100 ppb.
[0516] According to various embodiments of the invention the marker
molecule can be, for example, furfural, hydroxy-methyl furfural,
products of furfural or hydroxy-methylfurfural condensation, color
compounds derived from sugar caramelization, levulinic acid, acetic
acid, methanol, galacturonic acid, or glycerol.
Exemplary Extracted Substrates
[0517] An additional aspect of some embodiments of the invention
relates to extracted pine wood. According to various exemplary
embodiments, the extracted wood comprises at least 35%, at least
40%, at least 45%, at least 50% cellulose or intermediate or
greater percentages on a dry weight basis. According to various
exemplary embodiments, the extracted wood comprises at least 7.4%,
at least 8%, at least 8.5%, at least 9% hemicelluloses or
intermediate or greater percentages on a dry weight basis.
According to various exemplary embodiments, the extracted wood
comprises less than 1.0%, less than 0.7%, less than 0.6%, less than
0.4%, less than 0.3% ash or intermediate or lesser percentages on a
dry weight basis. In some embodiments, the extracted wood comprises
less than 2%, less than 1.5%, less than 1% or intermediate or
lesser percentages of DCM extractives on a dry weight basis. In
some embodiments, the extracted wood comprises less than 50%, less
than 30%, less than 20%, less than 10% or intermediate or lesser
percentages of the moisture content of said pine wood prior to
extraction. In some embodiments, at least 10%, at least 20%, at
least 30%, at least 40% or intermediate or higher percentages of
the cells are disrupted. In some embodiments, the extracted wood
comprises acetone and/or a weak acid.
Exemplary Extraction Mixtures
[0518] An additional aspect of some embodiments of the invention
relates to an extraction mixture. The extraction mixture comprises
one part lignocellulosic substrate and at least 2 parts, and/or
less than 3 parts, acetone, on a weight basis. In some embodiments,
the extraction mixture includes a weak acid, such as acetic acid
and/or sulfurous acid. In some embodiments, the extraction mixture
includes added water.
Exemplary Advantages
[0519] Practice of various methods described hereinabove can
influence the composition of hydrolyzate 270 (FIG. 3).
Specifically, impurities removed in miscella 130 will not be
present in hydrolyzate 270.
[0520] While it is possible to remove these impurities from
hydrolyzate 270 after its formation, it can be advantageous to be
spared such a post-hydrolysis removal. Advantages may be related to
complexity of industrial processes and/or costs.
[0521] Referring again to FIG. 3: in general, these advantages stem
from the fact that the ratio of soluble sugars to all hydrolyzate
components other than water and HCl will tend to be higher in a
hydrolyzate 270 produced in a system with an extraction module 310
and/or disruption module 340 than a comparable hydrolyzate produced
in a system which does not include such modules.
[0522] In some embodiments, implementation of a disruption module
340 in conjunction with extraction module 310 provides an
incremental advantage relative to use of extraction module 310
without disruption module 340 in terms of the ratio of soluble
sugars to all hydrolyzate components other than water and HCl in
hydrolyzate 270.
[0523] Alternatively or additionally, increasing the ratio of
soluble sugars to all hydrolyzate components other than water and
HCl can improve materials flow in hydrolysis module 320 and/or an
exit therefrom and/or downstream processing equipment (not
depicted). In some embodiments, this improvement in materials flow
can be related changes in viscosity of a liquid phase of
hydrolyzate 270 and/or behavior of un-dissolved solids (e.g.
lignin) in the hydrolyzate. These improvements in materials flow
may be most easily observable in system components such as filters,
drains and pumps.
[0524] Alternatively or additionally, lignin present in hydrolyzate
270 will not have impurities removed in miscella 130 associated
with it. Again, while it is possible to remove these impurities
from lignin after its separation from hydrolyzate 270, it can be
advantageous to be spared such a post hydrolysis removal. As with
sugars, advantages may be related to complexity of industrial
processes and/or costs. With regard to lignin, impurities such as
DCM extractives and ash (e.g. sulfates and phosphates) are
particularly relevant.
Additional Exemplary Advantages
[0525] Referring again to FIG. 1: removal of miscella 130 has been
described above in terms of how it improves a filtration rate of
lignin from hydrolyzate 270. Alternatively or additionally,
implementation of extracting 120 with extractant 110 to separate
miscella 130 and/or 240 from the substrate can make one or more
other improvements to downstream processing of extracted substrate
140 and/or 230 and/or hydrolyzate 270.
[0526] In some embodiments, extracting 120 contributes to a
reduction in a rate of fouling of filters of lignin by 10%, 20%,
30%, 40% or even 50% or more. Alternatively or additionally, in
some embodiments, extracting 120 contributes to a reduction in a
rate of fouling of resin used in chromatographic-separation of
sugars in hydrolyzate 270 by 10%, 20%, 30%, 40% or even 50% or
more. Exemplary chromatographic resins and their use in sugar
separation are described on co-pending applications IL 211093 and
U.S. 61/524,839; each of which is fully incorporated herein by
reference. Alternatively or additionally, in some embodiments,
extracting 120 contributes to a reduction in a rate of fouling of
filters used to filter undefined particulate matter from
hydrolyzate 270 by 10%, 20%, 30%, 40% or even 50% or more.
Alternatively or additionally, in some embodiments, extracting 120
contributes to a reduction in a rate of clogging of nozzles used in
a thermal process (e.g. pyrolysis and/or gasification) and/or in
reactive fluid treatment by 10%, 20%, 30%, 40% or even 50% or
more.
[0527] Alternatively or additionally, in some embodiments,
extracting 120 contributes to a reduction in amount of solids
filtered by various filters in the system by 10%, 20%, 30%, 40% or
even 50% or more.
[0528] Alternatively or additionally, in some embodiments,
extracting 120 contributes to a reduction in clumping of lignin in
lignin stream 260 by 10%, 20%, 30%, 40% or even 50% or more.
Exemplary Method Described in Detail
[0529] Referring again to FIG. 1: In some embodiments, substrate
100 is provided as pine wood chips and thermo-mechanical treatment
103 includes steam explosion (e.g. with a severity factor of about
3.8). In some embodiments, extracting 120 employs an extractant 110
including acetone and 0.005% to 0.01% by weight of acetic acid in a
mixture with water. Miscellae 130 and/or 240 are removed and
extractant 110 is regenerated from them as described hereinabove.
Following drying 221, dried extracted substrate 230 is hydrolyzed
250 in 42% HCl(HCL+water) by weight to produce hydrolyzate 270 and
lignin stream 260.
Exemplary Compositions
[0530] In some embodiments of the invention, there is provided a
lignocellulosic composition including (on a dry matter basis)
cellulose, hemicellulose, lignin and characterized by one or more
of the following characteristics.
[0531] In some embodiments, the composition is characterized by
less than 5,000 PPM, less than 3,000 PPM, less than 2,000 PPM, less
than 1,000 PPM, or less than 500 PPM lipophilic material.
[0532] Alternatively or additionally, in some embodiments, the
composition is characterized by less than 5,000 PPM, optionally
less than 3,000 PPM, optionally less than 2,000 PPM, optionally
less than 1,000 PPM, optionally less than 500 PPM ash.
[0533] Alternatively or additionally, in some embodiments, the
composition is characterized by less than 2,000 PPM, less than
1,500 PPM, less than 1,000 PPM, or less than 500 PPM Calcium.
[0534] Alternatively or additionally, in some embodiments, the
composition is characterized by less than 10,000 PPM, less than
8,000 PPM, less than 6,000 PPM, less than 4,000 PPM, less than
2,000 PPM, or less than 1,000 PPM pectin. Alternatively or
additionally, in some embodiments, the composition is characterized
by less than 2,000 PPM, optionally less than 1,500 PPM, optionally
less than 1,000 PPM, optionally less than 500 PPM furfural.
Alternatively or additionally, the composition is characterized by
at least 10 PPM marker selected from the group consisting of:
furfural, organically-bound sulfur, and a water soluble solvent
(e.g. acetone).
[0535] Alternatively or additionally, the composition is
characterized by a moisture content of 5% to 30%, 8% to 25%, or 10%
to 20%.
[0536] According to various exemplary embodiments of the invention
the composition is characterized by at least two, at least three,
at least four, or at least five of the characteristics set forth
above.
[0537] FIG. 9 depicts an exemplary method for processing a
lignocellulosic material according to some embodiments of the
invention indicated generally as 900. Depicted exemplary method 900
includes providing a lignocellulosic feed material 902 comprising
at least one polysaccharide and lignin. Any lignocellulosic
material is suitable. According to various exemplary embodiments of
the invention lignocellulosic material 902 is selected from the
group consisting of wood, sugarcane bagasse, oil palm biomass,
agricultural residues, biomass crops or recycled biomass. In some
embodiments, providing lignocellulosic material 902 includes
pretreatment 910. Optionally, pretreatment 910 includes comminuting
and/or desolventizing. In some embodiments, excess heat E4 from the
pyrolysis described hereinbelow provides energy for pretreatment
910.
[0538] In the depicted embodiment treated lignocellulosic material
904 is hydrolyzed 920 so that at least a fraction of the
polysaccharide is converted to an acidic (e.g. HCl) hydrolyzate 932
which is separated 930 from lignin stream 934.
[0539] Hydrolyzate 932 includes at least one carbohydrate and HCl
and lignin stream 934 includes solid lignin, HCl and water. In some
embodiments, the hydrolysis medium is formed by contacting
lignocellulosic material 902 with a recycled reagent HCl stream
(recycled reagents 928). In an embodiment, the HCl concentration in
the hydrolysis medium is in the range between 25% and 50% wt, as
calculated by HCl weight divided by the combined weights of HCl and
water multiplied by 100. In some embodiments, the HCl concentration
in the hydrolysis medium is in the range between 35% and 38% wt or
between 30% and 36% wt.
[0540] In some embodiments, hydrolysis 920 is not performed to its
full extent; leaving a significant ratio of the polysaccharides in
insoluble state. In some embodiments, the lignin stream comprises
residual insoluble polysaccharide and the residual insoluble
polysaccharides constitute at least 5% of the insoluble
polysaccharide in lignocellulosic material 902, at least 10%.
Alternatively or additionally, the residual insoluble
polysaccharides constitute less than 30% of the insoluble
polysaccharide in lignocellulosic material 902, optionally less
than 20%. In some embodiments, at least 50% of the residual
insoluble polysaccharide is crystalline, optionally at least 70% or
even at least 90%. Different parts of the polysaccharide
composition of lignocellulosic material 902 hydrolyze at different
rates. In some embodiments, the residual insoluble polysaccharide
is mainly cellulose, optionally more than 80% cellulose. In some
cases, the cellulose of the residual insoluble polysaccharide
differs from the cellulose in the lignocellulosic feed, e.g. in its
average molecular weight and/or in its degree of crystallinity.
[0541] According to various exemplary embodiments of the invention
relaxing the requirements for the extent of hydrolyzation of the
polysaccharides contained in lignocellulosic material 902 allows
the use of lower acid concentration in the hydrolysis medium, which
in turn reduces the costs of handing and recycling of the acid and
optionally reduces the required residence time of lignocellulosic
material 902 in contact with the hydrolysis medium, enabling higher
throughput for a fixed size facility.
[0542] The depicted embodiment includes separating 930 hydrolyzate
932 from lignin stream 934. Any method of separating is suitable.
According to an embodiment, separating 930 includes filtration
and/or centrifugation.
[0543] The depicted embodiment includes de-acidifying 940 and
optionally further treating hydrolyzate 932 to form a de-acidified,
carbohydrate-comprising hydrolyzate 942 and recovered reagent R1.
In some embodiments, HCl and water are separated from separated
hydrolyzate 932 to form acid-depleted hydrolyzate 942 and recovered
acid in a process comprising at least one of extraction with an S1
solvent and distillation.
[0544] As used in this specification and the accompanying claims
the term "S1 solvent" or "S1" indicates an organic solvent with a
solubility in water of less than 15% wt, optionally less than 5%
wt, optionally less than 2% wt and optionally less than 1% wt.
Alternatively or additionally, the solubility of water in S1 is
less than 20% wt, optionally less than 15% wt, optionally less than
10% wt and optionally less than 8% wt. S1 is further characterized
by at least one of: (1) having a delta-P between 5 and 10
MPa.sup.1/2, optionally between 6 and 9 MPa.sup.1/2 and optionally
between 6.5 and 8.5 MPa.sup.1/2 and (b) having a delta-H between 5
and 20 MPa.sup.1/2, optionally between 6 and 16 MPa.sup.1/2 and
optionally between 8 and 14 MPa.sup.1/2, wherein delta-P is the
polarity related component of Hoy's cohesion parameter and
delta-His the hydrogen bonding related component of Hoy's cohesion
parameter.
[0545] According to various exemplary embodiments of the invention
the boiling point of S1 is greater than that of water, optionally
greater than 120.degree. C. at atmospheric pressure, optionally
greater than 140.degree. C., and optionally greater than
160.degree. C. Alternatively or additionally, the boiling point of
S1 is lower than 250.degree. C. at atmospheric pressure, optionally
lower than 220.degree. C., and optionally lower than 200.degree.
C.
[0546] In some embodiments, S1 forms a heterogeneous azeotrope with
water. In some embodiments, in the heterogeneous azeotrope with
water, the ratio of S1 to water is in the range between 50 and 0.02
weight/weight, between 5 and 0.2, between 4 and 0.25, between 3 and
0.3, or between 2 and 0.5. According to an embodiment, the boiling
point of the heterogeneous azeotrope at atmospheric pressure is
less than 100.degree. C.
[0547] For example, S1 may be selected from the group consisting of
aliphatic or aromatic alcohols, ketones and aldehydes having at
least 5 carbon atoms, e.g. various pentanols, hexanols, heptanols,
octanols, nonanols, decanols, methyl-isobutyl-ketone and
methyl-butyl-ketone and combinations thereof. As used herein, the
term alcohols means any of mono-, di- and poly-alcohols, primary,
secondary and tertiary ones, straight chain and branched alcohols
and any combination of those. In some embodiments, S1 is selected
from hexanol and 2-ethyl-1-hexanol and mixtures thereof.
[0548] In some embodiments, the recovered acid (part of R1) is
optionally treated by mixing with at least one other
acid-comprising stream (e.g. R2) and/or concentration (reagents
recycling 950) to form recycled reagents 928. According to an
embodiment excess heat E2 from the pyrolysis described herein
provides at least part of the energy for the energy requirement for
de-acidification 940 and further treatment.
[0549] According to an embodiment said acid depleted hydrolyzate is
further treated to form the de-acidified, carbohydrate-containing
hydrolyzate. According to an embodiment said treating of said
de-acidified hydrolyzate comprises at least one of extraction with
an organic solvent and chromatographic separation.
[0550] In some embodiments, formation of the de-acidified
hydrolyzate includes removal of dissolved solvent and/or active
carbon treatment and/or ion-exchange treatment and/or
concentration.
[0551] In some embodiments, excess heat E2 from the pyrolysis step
described herein provides energy for formation of de-acidified
hydrolyzate 942.
[0552] In some embodiments, the depicted method includes processing
960 of de-acidified hydrolyzate 942 into at least one hydrolyzate
product 962. In some embodiments, processing 960 includes
fractioning and/or separating and/or purifying carbohydrates,
and/or hydrolyzing oligomers and/or chemical conversion or
biological conversion of carbohydrates in hydrolyzate 942 to form a
product comprising medium and/or product recovery from the medium
and/or product purification. In some embodiments, processing 960
includes fermenting carbohydrates in de-acidified hydrolyzate 942
to form product 962 in fermentation broth, separating the product
from the fermentation broth and purifying said product. According
to various exemplary embodiments of the invention product 962 is
selected from the group consisting of ethanol, butanol, other
alcohols, amino acids, carboxylic acids and monomers for the
polymer industry. In some embodiments, excess heat E5 from the
pyrolysis step provides energy for processing 960.
[0553] In some embodiments, the depicted method includes
de-acidifying 990 lignin stream 934 to form de-acidified lignin 992
and a second recovered acid stream R2. In some embodiments, lignin
de-acidification 990 includes contacting with a solvent and/or
distillation. In some embodiments, lignin de-acidification 990
includes contacting with an S1 solvent or a similar solvent
followed by desolventization.
[0554] In some embodiments, an HCl to lignin weight ratio in
de-acidified lignin 992 is less than 0.01, less than 0.005 or less
than 0.002. Alternatively or additionally, de-acidified lignin 992
is a solid composition including primarily lignin/ In some
embodiments, preferably at least 60%, or even at least 80% of
de-acidified lignin 992 is lignin. In some embodiments,
de-acidified lignin 992 includes residual insoluble
polysaccharide.
[0555] In some embodiments, lignocellulosic material 902 includes
extractives. As used in the context of material 902, the term
"extractives" includes tall oil, resin acids, fatty acids,
triglycerides and volatile organic compounds. In some embodiments,
de-acidified lignin 992 comprises at least 50% of the extractives
from lignocellulosic material 902, optionally at least 70%.
[0556] In some embodiments, second recovered acid stream R2 in FIG.
9 is further treated in reagents recycling 950 to form recovered
acid (part of recycled reagents 928).
[0557] Alternatively or additionally, in some embodiments, excess
heat from the pyrolysis step described herein provides energy (E6
and E1 respectively) lignin de-acidification 990 and/or reagents
recycling 950.
[0558] In some embodiments, method 900 includes treating
de-acidified lignin 992 at an elevated temperature (e.g. by
pyrolysis), in an oxygen-deficient atmosphere (oxygen deficient
treating 980) to form at least one primary lignin product 982 and
optionally converting said primary lignin product to at least one
secondary lignin product P10 and producing excess heat (E1, E2, E3,
E4, E5, E6 and E7). According to various exemplary embodiments of
the invention treating 980 includes pyrolysis and/or gasification.
In some embodiments, primary lignin product 982 is selected from
the group consisting of biocrude, hydrogen, carbon mono-oxide and
carbon dioxide.
[0559] Since pyrolysis is exthothermic, heat is produced treating
980 de-acidified lignin 992. Heat energy so produced can be used
directly and/or converted to electricity.
[0560] In some embodiments, de-acidified lignin 992 is combined
with additional biomass 984 in treating 980.
[0561] In some embodiments, primary lignin product 982, optionally
combined with additional biomass 984, is converted into at least
one secondary lignin product P10. In some embodiments, the
converting includes at least one of chemically catalyzed conversion
and biocatalyzed conversion. In some embodiments, the biocatalyzed
conversion includes fermentation of the primary lignin products as
such or after some adjustment.
[0562] In some embodiments, secondary lignin product P10 is
selected from the group consisting of ethanol, butanol, other
alcohols, amino acids, carboxylic acids and monomers for the
polymer industry.
[0563] In some embodiments of method 900, the carbon contents of
lignocellulosic material 902, of de-acidified hydrolyzate 942 and
of primary lignin products 982 are M1, M2 and M3, respectively, and
(M2+M3)/M1 is greater than 0.85, optionally greater than 0.90 and
optionally greater than 0.95.
[0564] In some embodiments, the depicted method, includes mixing
and processing 970 at least a fraction of de-acidified hydrolyzate
941 with at least a fraction of primary lignin product(s) 982
together. In some embodiments, primary lignin product 982 provides
a carbon source for fermentation and it is combined with
hydrolyzate 942 to form a combined fermentation carbon source
mixture.
[0565] Alternatively or additionally, method 900 includes reacting
or combining hydrolyzate product 962 with at least one of primary
lignin product 982 and secondary lignin product P10. In some
embodiments, the hydrolyzate product is a bio-fuel, and the lignin
product is bio-crude and at least a fraction of the bio-fuel is
combined with at least a fraction of the bio-crude to form a mixed
fuel. Alternatively or additionally, the hydrolyzate product is
acetic acid and the lignin product is hydrogen, and the acetic acid
is reacted with the hydrogen to form ethanol. Alternatively or
additionally, the hydrolyzate product or a product thereof includes
a double bond, e.g. an alkene formed from an alcohol, the lignin
product is hydrogen and the alkene is reacted with said hydrogen to
form an alkane.
[0566] In some embodiments, processing 960 of de-acidified
hydrolyzate 942 generates a carbon-containing co-product 964, and
the method includes combining co-product 964 with de-acidified
lignin 992 to form a combined product, which combined product is
then thermally treated (at 980). In some embodiments, de-acidified
hydrolyzate 942 includes non-fermentable compounds. In some
embodiments, these non-fermentable compounds are separated prior to
fermentation and combined with de-acidified lignin 992 to form the
combined product. Alternatively or additionally, in some
embodiments, non-fermentable compounds are kept in the fermentation
feed, are separated from the product broth and combined with
de-acidified lignin 992, optionally along with fermentation
biomass, to form the combined products.
[0567] According to various exemplary embodiments of the invention
of method 900 excess heat, or energy from the heat, (illustrated by
dotted arrows) is used in at least one of pretreatment 910 (E4),
reagents recycling 950 (E1), de-acidifying 940 (E2), de-lignin
de-acidification 990 (E6), hydrolyzing 290 (E7) and processing 960
(E5). Alternatively or additionally, excess heat, or energy from
the heat from one reaction in oxygen deficient treating 980 is used
to drive another reaction in oxygen deficient treating 980
(E3).
Additional Exemplary Methods
[0568] FIG. 10a is a schematic representation of a method for
biomass treatment indicated generally as 1000.
[0569] In some exemplary embodiments of the invention, method 1000
is for the continuous treatment of biomass and includes a
pretreatment step 1010 in which biomass 1012 is contacted with a
first supercritical, near-critical, or sub-critical fluid 1013 to
form a solid matrix 1016 and a first liquid fraction 1018. Depicted
exemplary method 1000 includes a hydrolysis step 1030 in which
solid matrix 1016 is contacted with a second supercritical or
near-critical fluid 1032 to produce a second liquid fraction 1028
and an insoluble lignin-containing fraction 1026.
[0570] In some embodiments, first fluid 1013 includes water and at
least one of SO.sub.2 and a solvent. In some embodiments, the
solvent is water-miscible and does not form an azeotrope with
water.
[0571] In some embodiments, second fluid 1032 includes water and at
least one of SO.sub.2 and a solvent. In some embodiments, the
solvent is water-miscible and does not form an azeotrope with
water.
[0572] In some embodiments, both first fluid 1013 and second fluid
1032 include water and at least one of SO.sub.2 and a solvent as
described above.
[0573] Referring again to FIG. 10a, in some embodiments, method
1000 includes a pretreatment step 1010 as described above which
forms a pretreated slurry 1015 including solid matrix 1016 and
first liquid fraction 1018 including xylo-oligosaccharides.
[0574] In some embodiments, the depicted method includes a first
separation step 1020 in which solid matrix 1016 and first liquid
fraction 1018 are separated and a first hydrolysis step 1030 in
which solid matrix 1016 is contacted second supercritical or
near-critical fluid 1032 to form an insoluble lignin-containing
fraction 1026 and a second liquid fraction 1028 including
cello-oligosaccharides.
[0575] In some embodiments, method 1000 includes a second
separation step 1040, in which insoluble lignin-containing fraction
1026 and second liquid fraction 1028 are separated. Alternatively
or additionally, in some embodiments method 1000 includes a second
hydrolysis step 1050 in which second liquid fraction 1028 is
contacted with a third near-critical or sub-critical fluid 1054 to
form a product 1056 including glucose monomers. In some
embodiments, third fluid 1054 includes water. In some embodiments,
third fluid 1054 includes acid.
[0576] Referring again to FIG. 10a, in some embodiments, method
1000 includes a pretreatment step 1010 as described above which
produces pretreated slurry 1015 as described above and first
separation step 1020 as described above and first hydrolysis step
1030 as described above to form insoluble lignin-containing
fraction 1026 and second liquid fraction 1028 including
cello-oligosaccharides.
[0577] In some embodiments, first fluid 1013 includes water and at
least one of SO.sub.2 and a solvent. In some embodiments, the
solvent is water-miscible and does not form an azeotrope with
water.
[0578] In some embodiments, method 1000 includes second separation
step 1040, in which insoluble lignin-containing fraction 1026 and
second liquid fraction 1028 are separated and second hydrolysis
step 1050 in which second liquid fraction 1028 is contacted with
third near-critical or sub-critical fluid 1054 to form a product
1056 including glucose monomers. In some embodiments, third fluid
1054 includes water. In some embodiments, third fluid 1054 includes
acid.
[0579] Referring again to FIG. 10a, in some embodiments, method
1000 includes a pretreatment step 1010 as described above wherein
the first supercritical or near-critical fluid 1013 includes water
and at least one of SO.sub.2 and a solvent. In some embodiments,
the solvent is water-miscible and does not form an azeotrope with
water. In some embodiments, method 1000 includes first separation
step 1020 and first hydrolysis step 1030 as described above to
produce insoluble lignin-containing fraction 1026 and a second
liquid fraction 1028 including cello-oligosaccharides. In some
embodiments, first fluid 1013 includes water and at least one of
SO.sub.2 and a solvent. In some embodiments, the solvent is
water-miscible and does not form an azeotrope with water. In some
embodiments, method 1000 includes a second separation step 1040 in
which insoluble lignin-containing fraction 1026 and second liquid
fraction 1028 are separated.
[0580] In some embodiments, method 1000 includes second hydrolysis
step 1050, in which second liquid fraction 1028 is contacted with
third near-critical or sub-critical fluid 1054 to form product 1056
including glucose monomers. In some embodiments, third fluid 1054
includes water and/or acid.
[0581] In some embodiments, method 1000 includes a second
separation step 1040 after hydrolysis 1030 which separates lignin
fraction 1026 and second liquid fraction 1028.
[0582] Alternatively or additionally, in some embodiments, method
1000 includes a second hydrolysis step 1050 in which second liquid
fraction 1028 is contacted with a third near-critical or
sub-critical fluid 1054 to produce a third liquid fraction
(depicted as product 1056) comprising glucose monomers. In some
embodiments, third fluid 1054 comprises water and/or an acid.
[0583] In some embodiments, method 1000 includes a first separation
step 1020 after pretreatment 1010 and prior to hydrolysis 1030 in
which solid matrix 1016 and first liquid fraction 1018 are
separated. In some embodiments, separation 1020 is performed using
an extruder or centrifugal press.
[0584] In some embodiments, pretreatment 1010 is continuous.
[0585] In various embodiments, second liquid fraction 1028 has a
residence time of 1 second, 10 seconds, 15 seconds, 20, seconds or
even about 30 seconds in second hydrolysis 1050.
[0586] Referring now to FIG. 10b: In some embodiments, method 1000
includes continues with method 1001. Depicted method 1001 includes
a xylo-oligosaccharide hydrolysis step 1060 in which first liquid
fraction 1018 is contacted with a fourth near-critical or
sub-critical fluid 1062 to produce a fourth liquid fraction 1064
comprising xylose monomers. In some embodiments, fourth fluid 1062
includes water. In some embodiments, fourth fluid 1062 includes an
acid.
[0587] Depicted exemplary method 1001 includes a third hydrolysis
step 1060, in which first liquid fraction 1018 (from method 1000)
is contacted with a fourth near-critical or sub-critical fluid 1062
to form a second product (fourth liquid fraction 1064) comprising
xylose monomers. In some embodiments, fourth fluid 1062 includes
water and/or acid.
Exemplary Fluid Parameters
[0588] According to various exemplary embodiments of the invention
first fluid 1013 includes at least 100 ppm, at least 500 ppm, at
least 1000 ppm or even at least 2000 ppm SO.sub.2. Alternatively or
additionally, first fluid 1013 includes less than 10%, less than
8%, less than 6%, or even less than 4% SO.sub.2. Alternatively or
additionally, first fluid 1013 includes at least 10%, at least 20%,
at least 30%, at least 40%, at least 50% or even at least 60%
solvent.
[0589] In some embodiments, second fluid 1032 includes at least 100
ppm, at least 500 ppm, at least 1000 ppm or even at least 2000 ppm
SO.sub.2. Alternatively or additionally, second fluid 1032
comprises less than 10%, less than 8%, less than 6%, or even less
than 4% SO.sub.2.
Exemplary Reaction Conditions
[0590] In some embodiments, pretreatment step 1010 occurs at a
temperature and pressure below the critical point of at least one
component of first fluid 1013.
[0591] According to various exemplary embodiments of the invention
pretreatment 1010 is performed at a temperature of about
100.degree. C., 125.degree. C., 150.degree. C., 175.degree. C.,
200.degree. C., 225.degree. C., 250.degree. C., 275.degree. C., or
even about 300.degree. C. or intermediate or higher
temperatures.
[0592] Alternatively or additionally, according to various
exemplary embodiments of the invention, pretreatment 1010 is
performed at a pressure of about 30 bar, 50 bar, 70 bar, 85 bar,
100 bar, 110 bar, or even about 115 bar or intermediate or higher
pressures.
[0593] In some embodiments, hydrolysis step 1030 occurs at a
temperature and pressure above the critical point of at least one
component of second fluid 1032.
[0594] In some embodiments, hydrolysis 1030 occurs at a temperature
of about 150.degree. C., 175.degree. C., 200.degree. C.,
250.degree. C., 300.degree. C., 350.degree. C., 400.degree. C., or
even 450.degree. C. or an intermediate or greater temperature.
Alternatively or additionally, hydrolysis 1030 occurs at a pressure
of about 100 bar, 125 bar, 150 bar, 175 bar, 200 bar, 225 bar, 240
bar or even about 250 bar or an intermediate or greater pressure.
In some embodiments, hydrolysis 1030 is continuous.
[0595] In some embodiments, solid matrix 1016 is kept at a
temperature of about 50.degree. C., 70.degree. C., 90.degree. C.,
110.degree. C., 130.degree. C. or even 150.degree. C., or
intermediate or higher temperatures from the beginning of
pretreatment 1010 step through at least the end of the hydrolysis
1030.
[0596] According to various exemplary embodiments of the invention
second hydrolysis 1050 occurs at a temperature of about 150.degree.
C., 175.degree. C., 200.degree. C., 225.degree. C., 250.degree. C.,
280.degree. C., 310.degree. C., or even 320.degree. C. or
intermediate or higher temperatures.
[0597] Alternatively or additionally, according to various
embodiments of the invention second hydrolysis 1050 occurs at a
pressure of about 20 bar, 30 bar, 40 bar, 50 bar, 60 bar, 70 bar,
80 bar, or even 90 bar or intermediate or higher pressures.
[0598] In various embodiments, xylo-oligosaccharide hydrolysis 1060
occurs at a temperature of about 150.degree. C., 175.degree. C.,
200.degree. C., 225.degree. C., 250.degree. C., 275.degree. C.,
300.degree. C., or even about 320.degree. C. or intermediate or
higher temperatures.
[0599] Alternatively or additionally, in various embodiments of the
invention xylo-oligosaccharide hydrolysis 1060 occurs at a pressure
of about 20 bar, 30 bar, 40 bar, 50 bar, 60 bar, 70 bar, 80 bar, or
even about 90 bar or intermediate or higher pressures.
[0600] In some embodiments, method 1000 includes reducing pressure
exerted on solid matrix 1016 such that the lignin precipitates
after hydrolysis 1030. In some embodiments, the pressure exerted on
solid matrix 1016 is reduced to about 110 kPa, 105 kPa, 90 kPa, 85
kPa, or even 80 kPa or less after hydrolysis 1030.
Exemplary Acid and Solvent Parameters
[0601] In some embodiments, the acid is present in a catalytic
amount or in an amount less than about 1%. The acid includes one or
more of hydrofluoric acid, hydrochloric acid, hydrobromic acid,
hydroiodic acid, sulfuric acid, sulfonic acid, phosphoric acid,
phosphonic acid, nitric acid and nitrous acid.
[0602] In some embodiments, the solvent is acetone.
[0603] In some embodiments, second fluid 1032 does not include an
acid.
Exemplary Yield Considerations
[0604] In some embodiments, first liquid fraction 1018 includes
xylose oligosaccharides. Alternatively or additionally, In some
embodiments, first liquid fraction 1018 includes an amount of
xylose oligosaccharides greater than about 50% of the maximum
theoretical yield.
[0605] In some embodiments, third liquid fraction (product 1056)
includes glycolaldehyde. In some embodiments, the glycolaldehyde is
present in an amount at least 10%, at least 20%, or even at least
30% of the theoretical maximum yield.
[0606] Use of super critical, near critical and subcritical fluids
in treatment of biomass is described in WO 2010/009343 and WO
2011/091044; each of which is fully incorporated herein by
reference.
[0607] It is expected that during the life of this patent many
apparatus for thermo-mechanical treatment of substrate 100 will be
developed and the scope of the invention is intended to include all
such new technologies a priori.
[0608] As used herein the term "about" refers to .+-.10%.
[0609] Although the invention has been described in conjunction
with specific embodiments thereof, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, it is intended to embrace
all such alternatives, modifications and variations that fall
within the scope of the appended claims.
[0610] Specifically, a variety of numerical indicators have been
utilized. It should be understood that these numerical indicators
could vary even further based upon a variety of engineering
principles, materials, intended use and designs incorporated into
the invention. Additionally, components and/or actions ascribed to
exemplary embodiments of the invention and depicted as a single
unit may be divided into subunits. Conversely, components and/or
actions ascribed to exemplary embodiments of the invention and
depicted as sub-units/individual actions may be combined into a
single unit/action with the described/depicted function.
[0611] Alternatively, or additionally, features used to describe a
method can be used to characterize an apparatus or system and
features used to describe an apparatus or system can be used to
characterize a method.
[0612] It should be further understood that the individual features
described hereinabove can be combined in all possible combinations
and sub-combinations to produce additional embodiments of the
invention. The examples given above are illustrative in nature and
do not limit the scope of the invention which is defined solely by
the following claims. Specifically, the invention has been
described in the context of lignocellulosic substrates but might
also be used in the context of other materials.
[0613] All publications, references patents and patent applications
mentioned in this specification are herein incorporated in their
entirety by reference into the specification, to the same extent as
if each individual publication, patent or patent application was
specifically and individually indicated to be incorporated herein
by reference. In addition, citation or identification of any
reference in this application shall not be construed as an
admission that such reference is available as prior art to the
present invention.
[0614] The terms "include", and "have" and their conjugates as used
herein mean "including but not necessarily limited to".
[0615] Additional objects, advantages, and novel features of
various embodiments of the invention will become apparent to one
ordinarily skilled in the art upon examination of the following
examples, which are not intended to be limiting. Additionally, each
of the various embodiments and aspects of the present invention as
delineated hereinabove and as claimed in the claims section below
finds experimental support in the following examples.
EXAMPLES
[0616] Reference is now made to the following examples, which
together with the above descriptions, illustrate the invention in a
non limiting fashion.
Example 1
Influence of Weak Acid on Extraction of Ash
[0617] In order to examine the effect of sulfurous acid on
extraction of ash, as represented by calcium and magnesium ions,
comparative extractions in the presence and absence of acid were
conducted.
[0618] Briefly, 5.5 gr pine wood (containing 38% water and about
0.3% ash on dry basis), 13.3 gr acetone, 0-1.8 gr 5% H2SO3 solution
and 0-1.74 gr water were introduced into vials.
[0619] In table 1, the initial composition of the reacted solvent
is given in terms of H2SO3 wt % and acetone-water to dry wood
ratio. For convenience, the extractions are grouped and ordered
according to H2SO3 wt %.
[0620] Vials were closed and shaken at 55.degree. C. for 4 hours.
Liquid was removed and filtered through 0.45 micron filter and
samples were taken for analysis and final composition of the
acetone solution at the end of the experiment is summarized in
Table 1; water content is determined by Karl Fisher test ASTM
D6869; ISO 15512 and indicated in the table by water KF, Ca.sup.+
Mg content is determined by titration and indicated in the table by
molls (N) and weight ratio and dry weight (solids in the table) is
determined by evaporation at 95.degree. C. for 3-4 hr.
[0621] Results presented in Table 1 demonstrate that substantially
no extraction of calcium and magnesium occurs in the absence of
sulfurous acid (vials 5,6 and 7) and that substantially all of the
calcium and magnesium is extracted in the presence of H.sub.250
(vials 1, 2, 3 and 4).
[0622] In addition, the total solids extraction (including
lipophilic material) is also improved in the presence of sulfurous
acid (vial 4).
[0623] This example illustrates that combination of a weak acid
with a water-soluble solvent can contribute to efficiency of
extraction of ash and/or lipophilic components from a
lignocellulosic substrate such as wood.
TABLE-US-00001 TABLE 1 sample composition before and after
extraction Before After extractant Miscella Miscella relative
Acetone- water to dry wood water/ H.sub.2SO.sub.3 KF** solids Ca +
Mg solids Ca + Mg* vial dry wood Wt % Wt % wt % N Wt % Wt % 1 5.04
0.10 16.3 0.289 0.0008 1.48 0.016 2 4.92 0.17 20.2 0.287 0.0031
1.43 0.060 3 5.35 0.20 24.9 0.266 0.0047 1.45 0.100 4 5.73 0.27
31.2 0.343 0.0062 2.00 0.142 5 4.34 0.00 16.4 0.167 0.0000 0.74
0.000 6 4.97 0.00 21.1 0.196 0.0000 0.99 0.000 7 5.08 0.00 23.6
0.306 0.0000 1.58 0.000 *Values in the table where determined by
titration and calculated according to the molecular weight of Ca.
Thus, the actual percentage is somewhat lower; **Karl Fisher
Example 2
Influence of Steam Explosion on Extraction
[0624] In order to examine the potential of a predetermined
pressure-temperature-time profile to improve extraction efficiency
three different steam explosion treatments were compared to three
negative control samples as summarized in table 2.
TABLE-US-00002 TABLE 2 Exemplary Steam explosion (SE) parameters
Steam explosion Pressure Sample type Duration (min) (bar) Symbol
Name experimental 2 15 square experimental 4 10 Triangle
experimental 2 12 Asterisk control NA NA Diamond NC original;
pre-hammer mill control NA NA X Hammer milled control NA NA Circle
Hammer milled
[0625] FIG. 4 is a plot of total solids extracted from dry wood (wt
%) as a function of extraction time in minutes.
[0626] The plotted data indicates that steam exploded (SE)
substrate was more amenable to extraction than either pre-hammer
milled (NC original) or hammer milled substrate.
[0627] The results also suggest that steam explosion at 15 bar was
more effective than steam explosion at 10 or 12 bar. Increasing
time at the high pressure did not seem to compensate for this
effect (compare squares to triangles).
[0628] Using steam explosion for 2 minutes at 15 bar, soluble
extractives were removed at ratios of up to 7%-9% from wood samples
that have been treated with steam explosion and then treated with
an extractant comprising acetone and sulphurous acid to remove
impurities. This is in sharp contrast to untreated wood or wood
treated by hammer milling before the extracting step, where at most
1.5-2.2% of extractives have been removed.
Example 3
Additional Acetone-SO.sub.2 Extraction
[0629] An additional extraction of pine wood was conducted using
about 15% water in acetone with an average SO2 content of 4120 PPM.
Extraction temperature was in the range of 50-55.degree. C.
[0630] Final moisture content of the miscella was determined,
mainly according to the solvent/wood ratio, as well as SO.sub.2
concentration. Volatiles in the extractor discharge to the
desolventizer were found to have a concentration of 62% average;
water in the miscella was 34.99% average, SO.sub.2 in the miscella
was 0.163% average; pH of the miscella was 4; pH at the bottom of
the evaporator was 3; and moisture in the desolventizer discharge
was 12%.
[0631] It is currently believed that the system will be able to
handle up to 12,000 PPM SO.sub.2 in acetone:water 90:10.
[0632] These results suggest that addition of SO.sub.2 to acetone
contributes to removal of cations during extraction. Overall
extraction efficiency appears to be in the range of 6-7% of the dry
wood weight. No significant loss of sugars is observed.
* * * * *
References