U.S. patent application number 14/850756 was filed with the patent office on 2016-01-07 for methods for detoxifying a lignocellulosic hydrolysate.
The applicant listed for this patent is BP Corporation North America Inc.. Invention is credited to Karen Kustedjo, Yukiko Sato, Malgorzata Slupska, Kelvin Wong.
Application Number | 20160002359 14/850756 |
Document ID | / |
Family ID | 47755019 |
Filed Date | 2016-01-07 |
United States Patent
Application |
20160002359 |
Kind Code |
A1 |
Slupska; Malgorzata ; et
al. |
January 7, 2016 |
METHODS FOR DETOXIFYING A LIGNOCELLULOSIC HYDROLYSATE
Abstract
The present disclosure relates to methods for detoxifying a
hydrolysate obtained from a lignocellulosic biomass and methods of
producing ethanol from the detoxified hydrolysate. The present
methods provide detoxified hydrolysates in which the quantity of
compounds that are deleterious to fermenting microorganisms are
substantially reduced relative to the starting hydrolysate and in
which the amount of fermentable sugars loss is minimal.
Inventors: |
Slupska; Malgorzata; (San
Diego, CA) ; Sato; Yukiko; (San Diego, CA) ;
Kustedjo; Karen; (San Diego, CA) ; Wong; Kelvin;
(San Diego, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BP Corporation North America Inc. |
Houston |
TX |
US |
|
|
Family ID: |
47755019 |
Appl. No.: |
14/850756 |
Filed: |
September 10, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13765039 |
Feb 12, 2013 |
9133278 |
|
|
14850756 |
|
|
|
|
61597973 |
Feb 13, 2012 |
|
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Current U.S.
Class: |
435/165 ;
127/37 |
Current CPC
Class: |
D21C 5/005 20130101;
Y02E 50/16 20130101; Y02E 50/10 20130101; D21C 1/06 20130101; D21C
3/02 20130101; C08B 1/003 20130101; C12P 2201/00 20130101; C12P
7/10 20130101; C12N 1/22 20130101; C08B 15/00 20130101 |
International
Class: |
C08B 1/00 20060101
C08B001/00; C12P 7/10 20060101 C12P007/10 |
Claims
1. A method of reducing the toxicity of a lignocellulosic
hydrolysate towards a fermenting organism, or for reducing at least
a portion of one inhibitor to a fermenting organism from a
lignocellulosic hydrolysate, comprising the step of mixing a
starting lignocellulosic hydrolysate solution, said starting
lignocellulosic hydrolysate solution comprising a mixture of
fermentable sugars, furan aldehydes and aliphatic acids, with a
magnesium base selected from magnesium hydroxide, magnesium
carbonate and magnesium oxide for a period of time and under
conditions that result in the formation of a detoxified hydrolysate
solution comprising at least 90% of the total fermentable sugars
present in the starting lignocellulosic hydrolysate solution and no
greater than 40% of furan aldehydes present in the starting
lignocellulosic hydrolysate solution, thereby reducing the toxicity
of the lignocellulosic hydrolysate.
2. The method of claim 1, wherein the starting hydrolysate solution
is prepared by hydrolyzing a lignocellulosic biomass.
3. The method of claim 2, wherein the lignocellulosic biomass is
selected from Napier grass, energy cane, sorghum, giant reed, sugar
beet, switchgrass, bagasse, rice straw, miscanthus, switchgrass,
wheat straw, wood, wood waste, paper, paper waste, agricultural
waste, municipal waste, birchwood, oat spelt, corn stover,
eucalyptus, willow, hybrid poplar, short-rotation woody crop,
conifer softwood and crop residue.
4. The method of claim 1, further comprising the step of
concentrating a hydrolysate solution to produce said starting
hydrolysate solution prior to said mixing step.
5. A method of reducing the toxicity of a lignocellulosic
hydrolysate towards a fermenting organism, comprising the step of
mixing a starting lignocellulosic hydrolysate solution, said
starting lignocellulosic hydrolysate solution comprising a mixture
of fermentable sugars, furan aldehydes and aliphatic acids, with a
magnesium base selected from magnesium hydroxide, magnesium
carbonate and magnesium oxide for a period of time of at least 1
hour, at least 4 hours, at least 10 hours or at least 20 hours at a
temperature between 40.degree. C. and 70.degree. C. and at a pH of
between 6.5 and 8, thereby reducing the toxicity of the
lignocellulosic hydrolysate.
6. The method of claim 5, wherein the magnesium base is magnesium
hydroxide.
7. The method of claim 5, wherein the magnesium base is magnesium
carbonate.
8. The method of claim 5, wherein the magnesium base is magnesium
oxide.
9. The method of claim 5, wherein the mixing is carried out for a
period of up to 4 hours.
10. The method of claim 5, wherein the pH is in the range is
between 7 and 8.
11. The method of claim 5, wherein the temperature is between
40.degree. C. and 70.degree. C.
12. The method of claim 5, wherein the temperature is between
40.degree. C. and 55.degree. C.
13. The method of claim 5, wherein mixing the starting hydrolysate
with the magnesium base is carried out in a batch reactor.
14. The method of claim 5, wherein mixing the starting hydrolysate
with the magnesium base is carried out in a continuous reactor.
15. The method of claim 14, wherein the continuous reactor is a
plug flow reactor (PFR).
16. The method of claim 15, wherein the continuous reactor is a
continuous stirred tank reactor (CSTR).
17. A method of producing a fermentation product, comprising the
step of culturing a fermenting microorganism in the presence of a
detoxified hydrolysate solution produced by the method of claim 1
under conditions in which ethanol is produced, thereby producing
the fermentation product.
18. The method of claim 17, farther comprising separating the
fermentation product from the culture.
19. The method of claim 17, wherein the fermenting organism
includes one or more of Escherichia coli, Zymomonas mobilis,
Bacillus stearothermophilus, Saccharomyces cerevisiae, Clostridia
thermocellum, Thermoanaerobacterium saccharolyticum, and Pichia
stipitis.
20. The method of claim 17, further comprising producing the
detoxified hydrolysate prior to said culturing step.
21. The method of claim 17, wherein the fermentation product is
ethanol.
22. A method for continuously reducing the quantity of toxins in a
hydrolysate, comprising the steps of: (a) flowing a first
continuous stream of the hydrolysate into a continuous reactor; (b)
flowing a second continuous stream of a magnesium base into the
continuous reactor; (c) mixing the hydrolysate with the magnesium
base in the continuous reactor or a series of continuous reactors
for a period of time sufficient to reduce the quantity of toxins in
the hydrolysate; and (d) flowing the hydrolysate out of the
continuous reactor or the series of continuous reactors.
23. The method of claim 22, wherein the magnesium base is selected
from magnesium hydroxide, magnesium carbonate and magnesium
oxide.
24. The method of claim 23, wherein the magnesium base is magnesium
hydroxide.
25. The method of claim 22, wherein the reactor is a plug flow
reactor (PFR).
26. The method of claim 22, wherein the reactor is a continuous
stirred tank reactor (CSTR).
27. The method of claim 22, further comprising concentrating the
hydrolysate prior to step (a).
28. A method for continuously producing a fermentation product,
comprising: (a) flowing a first continuous stream of a hydrolysate
into a continuous reactor; (b) flowing a second continuous stream
of a magnesium base into the continuous reactor; (c) mixing the
hydrolysate with the magnesium base in the continuous reactor or a
series of continuous reactors for a period of time sufficient to
reduce the quantity of furan aldehydes in the hydrolysate; (d)
flowing the hydrolysate out of the continuous reactor or the series
of continuous reactors; (e) reducing the pH of the hydrolysate; and
(f) flowing the hydrolysate into a fermentation vessel containing a
fermenting microorganism, thereby producing the fermentation
product.
29. The method of claim 28, wherein the magnesium base is selected
from magnesium hydroxide, magnesium carbonate and magnesium
oxide.
30. The method of claim 29, wherein the magnesium base is magnesium
hydroxide.
31. The method of claim 28, wherein the reactor is a plug flow
reactor (PFR).
32. The method of claim 28, wherein the reactor is a continuous
stirred tank reactor (CSTR).
33. The method of claim 28, farther comprising concentrating the
hydrolysate prior to step (a).
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S.
application Ser. No. 13/765,039 filed Feb. 12, 2013, now issued as
U.S. Pat. No. 9,133,278; which claims the benefit under 35 USC
.sctn.119(e) to U.S. Application Ser. No. 61/597,973 filed Feb. 13,
2012, now expired. The disclosure of each of the prior applications
is considered part of and is incorporated by reference in the
disclosure of this application.
BACKGROUND OF THE INVENTION
[0002] Many industrial products are produced by microorganisms
grown in culture. Microorganism growth may be supported by soluble
sugar molecules released by lignocellulosic biomasses.
Lignocellulosic biomasses consist primarily of cellulose (polymers
of glucose linked by .beta.-1,4-glucosidic bonds), hemicellulose
(polysaccharide composed of different five (C5)--carbon sugars and
six (C6)--carbon sugars linked by variety of different .beta. and
.alpha. linkages) and lignin (complex polymer consisting of phenyl
propane units linked by ether or carbon-carbon bonds). In some
cases, lignocellulosic biomasses are subject to dilute acid
hydrolysis during which hemicellulose is hydrolyzed to monomeric
sugars (liquid stream) and the crystalline structure of cellulose
is damaged, facilitating future enzymatic digestion (solid fiber).
The liquid containing C5 and C6 sugars, so called hydrolysate, is
separated from cellulose and lignin solids and can be fermented to
various products such as ethanol. In addition to sugars however,
hydrolysate also contains aliphatic acids, esters (acetate),
phenolics (different compounds obtained from lignin hydrolysis) and
products of sugar dehydration, including the furan aldehydes
furfural and 5-hydroxymethyl furfural (5-HMF). Most of these
compounds have a negative impact on microorganisms and can inhibit
fermentation. Detoxification of the hydrolysate prior to
fermentation is one measure that can be taken in order to avoid
inhibition caused by toxic compounds present in the
hydrolysate.
[0003] Various methods of detoxification have been tested, with
alkaline overliming being efficient and cost effective. During the
overliming process, the pH of the hydrolysate is temporarily
raised, usually at an elevated temperature, from a pH of
approximately 2 to a pH of between 9 and 10 through the addition of
an appropriate amount of calcium hydroxide (lime). After some time,
typically about 30 minutes, the pH of the hydrolysate solution is
lowered through the addition of acid to a pH suitable for
fermenting microorganisms. In the detoxification process, furan
aldehydes are degraded and acids (mineral and organic) are
neutralized.
[0004] Overliming has been known for a long time (Leonard and
Hajny, 1945, Ind. Eng. Chem., 37 (4):390-395) and still is
considered an efficient detoxification method. However, a
significant drawback of the method is the considerable amount of
loss of fermentable sugars that occurs during detoxification. See,
e.g., Larsson et al., 1999, Appl. Biochem. Biotechnol.
77-79:91-103. The loss of fermentable sugars results in lower
overall yields of fermentable products such as ethanol. In
addition, the formation of insoluble calcium sulfate (gypsum)
during detoxification is problematic. See, e.g., Martinez et al.,
2001, Biotechnol. Prog. 17(2):287-293. Gypsum formation causes
fouling and pipeline clogging, which significantly drive up
maintenance costs. To overcome problems associated with calcium
hydroxide, other bases have been attempted for the purpose of
hydrolysate detoxification, which have met with varying levels of
success. See, e.g., Alriksson et al., 2005, Appl. Biochem.
Biotechnol. 121-124:911-922.
[0005] Accordingly, there is a need for new and improved processes
to reduce fermentation inhibitors and detoxify hydrolysates
obtained from lignocellulosic biomasses. In particular, there is a
need for detoxification processes that are economically viable and
provide detoxified hydrolysates capable of producing high yields of
ethanol.
SUMMARY OF THE INVENTION
[0006] The present disclosure stems from the discovery that
magnesium bases (e.g., magnesium hydroxide, magnesium carbonate, or
magnesium oxide) can effectively detoxify hydrolysates obtained
from lignocellulosic biomasses (sometimes referred to herein as
"lignocellulosic hydrolysates"), and that the detoxification
process results in minimal losses of fermentable sugars. As used
herein, the term "detoxification" refers to a process in which one
or more compounds that are detrimental to a fermenting
microorganism (referred to herein as "toxins") are removed from a
starting lignocellulosic hydrolysate or inactivated, thereby
forming a detoxified hydrolysate. As used herein, the phrase
"detoxified hydrolysate" refers to a hydrolysate containing lower
toxin levels than the toxin levels in the hydrolysate prior to the
treatment with a magnesium base, referred to herein as a "starting
hydrolysate". Such toxins include, but are not limited to, furan
aldehydes, aliphatic acids, esters and phenolics.
[0007] Magnesium bases offer significant advantages over calcium
hydroxide as detoxification bases. For instance, detoxification
with magnesium bases results in less sugar burn than detoxification
with calcium hydroxide. Additionally, detoxification with magnesium
bases does not result in the production of insoluble byproducts
that cause fouling and pipeline clogging which significantly drive
up maintenance costs.
[0008] The hydrolysate detoxification methods of the present
disclosure find application in the production of fuel molecules
such as ethanol. When a hydrolysate is treated with a magnesium
base for a sufficient time to remove or inactivate one or more
toxins, the resultant detoxified lignocellulosic hydrolysate can be
more effectively fermented by a fermenting microorganism (e.g.,
ethanologen) to produce a fermentation product such as ethanol. In
exemplary embodiments involving ethanol fermentation, the quantity
of ethanol generated by detoxified hydrolysates produced in
accordance with the present disclosure is comparable to quantity of
ethanol produced by hydrolysates that are detoxified with calcium
hydroxide (see Example 5).
[0009] Accordingly, the disclosure generally provides methods of
reducing the toxicity of a lignocellulosic hydrolysate towards a
fermenting organism. In certain aspects, the methods involve mixing
a solution of a starting hydrolysate (i.e., starting hydrolysate
solution) with a magnesium base (e.g., magnesium hydroxide,
magnesium carbonate or magnesium oxide) for a period of time and
under conditions that result in the production of a solution of a
detoxified hydrolysate (i.e., detoxified hydrolysate solution). The
methods of the present disclosure provide detoxified hydrolysates
in which the quantity of the toxins that are deleterious to
fermenting microorganisms is substantially reduced relative to the
starting hydrolysate. At the same time, the amount of fermentable
sugars lost in the detoxification process is minimal.
[0010] In certain embodiments, the methods disclosed herein result
in the production of a detoxified hydrolysate with at least 70%, at
least 80%, at least 85%, at least 90%, at least 92%, at least 93%,
at least 95% or at least 99% of the fermentable sugars present in
the starting hydrolysate and no greater than 70%, no greater than
60%, no greater than 50%, no greater than 40%, no greater than 30%,
no greater than 20% or no greater than 10% of the furan aldehydes
present in the staring hydrolysate. In particular embodiments,
detoxification methods of the present disclosure provide a
detoxified hydrolysate with (a) at least 90% of the total
fermentable sugars present in the starting hydrolysate and no
greater than 50% of the furan aldehydes present in the starting
hydrolysate; (b) at least 90% of the total fermentable sugars
present in the starting hydrolysate and no greater than 40% of the
furan aldehydes present in the starting hydrolysate; (c) at least
90% of the total fermentable sugars present in the starting
hydrolysate and no greater than 30% of the furan aldehydes present
in the starting hydrolysate; (d) at least 90% of the total
fermentable sugars present in the starting hydrolysate and no
greater than 20% of the furan aldehydes present in the starting
hydrolysate; (e) at least 80% of the total fermentable sugars
present in the starting hydrolysate and no greater than 50% of the
furan aldehydes present in the starting hydrolysate; (f) at least
80% of the total fermentable sugars present in the starting
hydrolysate and no greater than 40% of the furan aldehydes present
in the starting hydrolysate; (g) at least 80% of the total
fermentable sugars present in the starting hydrolysate and no
greater than 30% of the furan aldehydes present in the starting
hydrolysate; or (h) at least 80% of the total fermentable sugars
present in the starting hydrolysate and no greater than 20% of the
furan aldehydes present in the starting hydrolysate.
[0011] The biomass is preferably lignocellulosic and can include,
without limitation, seeds, grains, tubers, plant waste or
byproducts of food processing or industrial processing (e.g.,
stalks), corn (including, e.g., cobs, stover, and the like),
grasses (including, e.g., Indian grass, such as Sorghastrum nutans;
or, switchgrass, e.g., Panicum species, such as Panicum virgatum),
wood (including, e.g., wood chips, processing waste), paper, pulp,
and recycled paper (including, e.g., newspaper, printer paper, and
the like). Other biomass materials include, without limitation,
potatoes, soybean (e.g., rapeseed), barley, rye, oats, wheat,
beets, and sugar cane bagasse. Further sources of biomass are
disclosed in Section 4.1 and can be used in the present
methods.
[0012] The concentration of the individual compounds of the
hydrolysate in the hydrolysate solution prior to detoxification
depends, in part, on the biomass from which the hydrolysate is
obtained and the method used to hydrolyze the biomass, as well as
hydrolysis conditions. In certain embodiments, the starting
hydrolysate solution comprises (a) fermentable sugars at a
concentration ranging from 30 g/L to 160 g/L, from 40 g/L to 95
g/L, or from 50 g/L to 70 g/L; (b) furfural at a concentration
ranging from 0.5 g/L to 10 g/L, from 2.5 g/L to 4 g/L, or from 1.5
g/L to 5 g/L; (c) 5-HMF at a concentration ranging from 0.1 g/L to
5 g/L, from 0.5 g/L to 2.5 g/L or from 1 g/L to 2 g/L; (d) acetic
acid at a concentration ranging from 2 g/L to 17 g/L or from 11 g/L
to 16 g/L; (e) lactic acid at a concentration ranging from 0 g/L to
12 g/L or from 4 g/L to 10 g/L; (f) additional aliphatic acids
(e.g., succinic acid, formic acid, butyric acid and levulinic acid)
at concentrations ranging from 0 g/L to 2.5 g/L; and/or (g)
phenolics at a concentration ranging from 0 g/L to 10 g/L, from 0.5
g/L to 5 g/L or from 1 g/L to 3 g/L.
[0013] The starting hydrolysate solution can be concentrated prior
to detoxification. For instance, following biomass hydrolysis, a
hydrolysate solution can be concentrated by 1.2-fold, 1.5-fold,
2-fold, 3-fold or 5-fold. In specific embodiments, the starting
hydrolysate is concentrated in a range bounded by any two of the
foregoing embodiments, e.g., concentrated in the range from 1-fold
to 3-fold, 1.5-fold to 3-fold, 3-fold to 5-fold, etc.
[0014] In various embodiments, the detoxification of the
lignocellulosic hydrolysate solution can be carried out at a
temperature ranging from 25.degree. C. to 90.degree. C. The
detoxification process can be carried out, for example at
30.degree. C., 35.degree. C., 40.degree. C., 45.degree. C.,
50.degree. C., 55.degree. C., 60.degree. C., 65.degree. C.,
70.degree. C., 75.degree. C., 80.degree. C., 85.degree. C., or
90.degree. C. In specific embodiments, the detoxification process
is carried out at a temperature in the range bounded by any two of
the foregoing temperatures, e.g., at a temperature ranging from
40.degree. C. to 60.degree. C., from 45.degree. C. to 50.degree.
C., from 35.degree. C. to 65.degree. C., etc. Advantageously, the
detoxification process is carried out at a temperature ranging from
40.degree. C. to 60.degree. C., which allows the detoxification
reactions to occur at a commercially feasible rate while minimizing
the loss of fermentable sugars, and thereby increasing the yield of
fermentation products (e.g., ethanol, biochemicals).
[0015] The hydrolysate detoxification process is typically carried
out at a pH ranging from 6.2 to9.5 For instance, the detoxification
can be carried out at a pH of 6.5, 7, 7.5, 8, 8.5, 9, or 9.5. In
specific embodiments, the detoxification process can be carried out
at a pH in the range bounded by any two of the foregoing values,
e.g., at a pH ranging from 6.5 to 8, from 7 to 8, etc.
[0016] In certain aspects, the disclosure provides for a method of
reducing the toxicity of a lignocellulosic hydrolysate towards a
fermenting organism, comprising the step of mixing a starting
lignocellulosic hydrolysate solution, said starting lignocellulosic
hydrolysate solution comprising a mixture of fermentable sugars,
furan aldehydes and aliphatic acids, with a magnesium base for a
period of time of at least 1 hour, at least 4 hours, at least 10
hours or at least 20 hours at a temperature between 40.degree. C.
and 70.degree. C. and at a pH of between 6.5 and 8. In particular
embodiments, the magnesium base is magnesium hydroxide.
[0017] The detoxification process can be carried out as a batch
process, as a continuous process, or as a semi-continuous process.
The detoxification process can be carried out in a batch reactor, a
continuous stirred tank reactor (CSTR), a series of continuous
stirred tank reactors, or a plug flow reactor (PFR).
[0018] The disclosure further provides methods for continuously
reducing the quantity of toxins in a hydrolysate, comprising the
steps of flowing a first continuous stream of a hydrolysate into a
continuous reactor or a series of continuous reactors, flowing a
second continuous stream of a solution of a magnesium base into the
continuous reactor or the series of continuous reactors, mixing the
hydrolysate with the magnesium base in the continuous reactor for a
period of time sufficient to reduce the quantity of toxins in the
hydrolysate, and flowing the hydrolysate out of the continuous
reactor.
[0019] The detoxified hydrolysates of the present disclosure can be
fermented by a fermenting microorganism to produce fermentation
products such as ethanol. Accordingly, the methods of the
disclosure further include culturing a fermenting microorganism in
the presence of a detoxified hydrolysate produced in accordance
with the present disclosure under conditions in which a
fermentation product is produced. Various fermenting microorganisms
(e.g., ethanologens) can be used to produce fermentable products
such as those described in Section 4.5.
[0020] Additionally, the disclosure provides methods for
continuously producing a fermentation product, comprising flowing a
first continuous stream of a hydrolysate into a continuous reactor
or a series of continuous reactors or the series of continuous
reactors, flowing a second continuous stream of a magnesium base
into the continuous reactor, mixing the hydrolysate with the
magnesium base in the continuous reactor for a period of time
sufficient to detoxify (i.e., reduce the quantity) of toxins in the
hydrolysate, flowing the hydrolysate out of the continuous reactor,
reducing the pH of the hydrolysate, and flowing the detoxified
hydrolysate into a fermentation vessel containing a fermenting
microorganism, thereby producing a fermentation product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1: Schematic of a flow diagram of an exemplary
continuous process of the present disclosure.
[0022] FIG. 2A: Graph depicting the amount of xylose and furfural
elimination at different time points for detoxification reactions
using 28.5 g magnesium hydroxide/1 kg hydrolysate performed at
50.degree. C.
[0023] FIG. 2B: Graph depicting the amount of xylose and furfural
elimination at different time points for detoxification reactions
using 85.5 g magnesium hydroxide/1 kg hydrolysate performed at
70.degree. C.
[0024] FIG. 2C: Graph depicting the amount of xylose and furfural
elimination at different time points for detoxification reactions
using 142.5 g magnesium hydroxide/1 kg hydrolysate performed at
90.degree. C.
[0025] FIG. 3: Titration curves of a hydrolysate obtained from a
sugar cane biomass using three different bases.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present disclosure relates to methods for detoxifying a
hydrolysate obtained from a biomass and methods of producing a
fermentation product (e.g., ethanol) from the detoxified
hydrolysate. Types of biomass that can be used in the present
methods include but are not limited to those described in Section
4.1. Methods of hydrolyzing the biomass are described in Section
4.2. Typical compositions of hydrolysates prior to detoxification
are described in Section 4.3. Methods of detoxifying the
hydrolysates using magnesium bases are described in Section 4.4.
Methods of fermenting the detoxified hydrolysate to produce
fermentation products are described in Section 4.5 and methods of
recovering the fermentation products are described in Section
4.6.
Biomass
[0027] The term "biomass," as used herein, refers to any
composition comprising cellulose (optionally also hemicellulose
and/or lignin).
[0028] Relevant types of biomasses which can be hydrolyzed or
detoxified according to the methods of the disclosure can include
biomasses obtained from agricultural crops such as, e.g.,
containing grains; corn stover, grass, bagasse, straw e.g., from
rice, wheat, rye, oat, barley, rape, sorghum; tubers, e.g., beet
and potato.
[0029] The biomass is preferably lignocellulosic. The
lignocellulosic biomass is suitably from the grass family. The
proper name is the family known as Poaceae or Gramineae in the
class Liliopsida (the monocots) of the flowering plants. Plants of
this family are usually called grasses, and include bamboo. There
are about 600 genera and some 9,000-10,000 or more species of
grasses (Kew Index of World Grass Species).
[0030] Poaceae includes the staple food grains and cereal crops
grown around the world, lawn and forage grasses, and bamboo.
[0031] The success of the grasses lies in part in their morphology
and growth processes, and in part in their physiological diversity.
Most of the grasses divide into two physiological groups, using the
C3 and C4 photo synthetic pathways for carbon fixation. The C4
grasses have a photosynthetic pathway linked to specialized leaf
anatomy that particularly adapts them to hot climates and an
atmosphere low in carbon dioxide. C3 grasses are referred to as
"cool season grasses" while C4 plants are considered "warm season
grasses".
[0032] Grasses may be either annual or perennial. Examples of
annual cool season are wheat, rye, annual bluegrass (annual
meadowgrass, Poa annua and oat). Examples of perennial cool season
are orchardgrass (cocksfoot, Dactylis glomerate), fescue (Festuca
spp.), Kentucky bluegrass and perennial ryegrass (Lolium perenne).
Examples of annual warm season are corn, sudangrass and pearl
millet. Examples of Perennial Warm Season are big bluestem,
indiangrass, bermudagrass and switchgrass.
[0033] One classification of the grass family recognizes twelve
subfamilies: These are 1) anomochlooideae, a small lineage of
broad-leaved grasses that includes two genera (Anomochloa,
Streptochaeta); 2) Pharoideae (aka Poaceae), a small lineage of
grasses that includes three genera, including Pharus and Leptaspis;
3) Puelioideae, a small lineage that includes the African genus
Puelia; 4) Pooideae which includes wheat, barley, oats, brome-grass
(Bromus) and reed-grasses (Calamagrostis); 5) Bambusoideae which
includes bamboo; 6) Ehrhartoideae, which includes rice, and wild
rice; 7) Arundinoideae, which includes the giant reed and common
reed; 8) Centothecoideae, a small subfamily of 11 genera that is
sometimes included in Panicoideae; 9) Chloridoideae including the
lovegrasses (Eragrostis, ca. 350 species, including teff), dropseed
grasses (Sporobolus, some 160 species), finger millet (Eleusine
coracana (L.) Gaertn.), and the muhly grasses (Muhlenbergia, ca.
175 species); 10) Panicoideae including panic grass, maize,
sorghum, sugar cane, most millets, fonio and bluestem grasses; 11)
Micrairoideae; 12) Danthoniodieae including pampas grass; with Poa
which is a genus of about 500 species of grasses, native to the
temperate regions of both hemisphere.
[0034] Agricultural grasses grown for their edible seeds are called
cereals. Three common cereals are rice, wheat and maize (corn). Of
all crops, 70% are grasses.
[0035] Therefore a preferred biomass is selected from the group
consisting of the energy crops. In a further preferred embodiment,
the energy crops are grasses. Preferred grasses include Napier
Grass or Uganda Grass, such as Pennisetum purpureum; or,
Miscanthus; such as Miscanthus giganteus and other varieties of the
genus miscanthus, or Indian grass, such as Sorghastrum nutans; or,
switchgrass, e.g., as Panicum virgatum or other varieties of the
genus Panicum), giant reed (arundo donax), energy cane (saccharum
spp.), wood (including, e.g., wood chips, processing waste), paper,
pulp, and recycled paper (including, e.g., newspaper, printer
paper, and the like). In some embodiments the biomass is sugarcane,
which refers to any species of tall perennial grasses of the genus
Saccharum.
[0036] Other types of biomass include seeds, grains, tuber (e.g.,
potatoes and beets), plant waste or byproducts of food processing
or industrial processing (e.g., stalks), corn and corn byproducts
(including, e.g., corn husks, corn cobs, corn fiber, corn stover,
and the like), wood and wood byproducts (including, e.g.,
processing waste, deciduous wood, coniferous wood, wood chips
(e.g., deciduous or coniferous wood chips), sawdust (e.g.,
deciduous or coniferous sawdust)), paper and paper byproducts
(e.g., pulp, mill waste, and recycled paper, including, e.g.,
newspaper, printer paper, and the like), soybean (e.g., rapeseed),
barley, rye, oats, wheat, beets, sorghum sudan, milo, bulgur, rice,
sugar cane bagasse, forest residue, agricultural residues, quinoa,
wheat straw, milo stubble, citrus waste, urban green waste or
residue, food manufacturing industry waste or residue, cereal
manufacturing waste or residue, hay, straw, rice straw, grain
cleanings, spent brewer's grain, rice hulls, salix, spruce, poplar,
eucalyptus, Brassica carinata residue, Antigonum leptopus,
sweetgum, Sericea lespedeza, Chinese tallow, hemp, rapeseed,
Sorghum bicolor, soybeans and soybean products (soybean leaves,
soybeans stems, soybean pods, and soybean residue), sunflowers and
sunflower products (e.g., leaves, sunflower stems, seedless
sunflower heads, sunflower hulls, and sunflower residue), Arundo,
nut shells, deciduous leaves, cotton fiber, manure, coastal Bermuda
grass, clover, Johnsongrass, flax, straw (e.g., barley straw,
buckwheat straw, oat straw, millet straw, rye straw amaranth straw,
spelt straw), amaranth and amaranth products (e.g., amaranth stems,
amaranth leaves, and amaranth residue), alfalfa, and bamboo.
[0037] Yet further sources of biomass include hardwood and
softwood. Examples of suitable softwood and hardwood trees include,
but are not limited to, the following: pine trees, such as loblolly
pine, jack pine, Caribbean pine, lodgepole pine, shortleaf pine,
slash pine, Honduran pine, Masson's pine, Sumatran pine, western
white pine, egg-cone pine, longleaf pine, patula pine, maritime
pine, ponderosa pine, Monterey pine, red pine, eastern white pine,
Scots pine, araucaria tress; fir trees, such as Douglas fir; and
hemlock trees, plus hybrids of any of the foregoing. Additional
examples include, but are not limited to, the following: eucalyptus
trees, such as Dunn's white gum, Tasmanian blue gum, rose gum,
Sydney blue gum, Timor white gum, and the E. urograndis hybrid;
populus trees, such as eastern cottonwood, bigtooth aspen, quaking
aspen, and black cottonwood; and other hardwood trees, such as red
alder, Sweetgum, tulip tree, Oregon ash, green ash, and willow,
plus hybrids of any of the foregoing.
Hydrolysis of Biomass
[0038] Any hydrolysis process can be used to prepare
lignocellulosic hydrolysates, including acid hydrolysis and base
hydrolysis. Acid hydrolysis is a cheap and fast method and can
suitably be used. A concentrated acid hydrolysis is preferably
operated at temperatures from 20.degree. C. to 100.degree. C., and
an acid strength in the range of 10% to 45% (e.g., 10%, 10.5%, 11%,
11.5%, 12%, 12.5%, 13%, 13.5%, 14%, 14.5%, 15%, 15.5%, 16%, 17%,
17.5%, 18%, 18.5%, 19%, 19.5%, 20%, 20.5%, 21%, 21.5%, 22%, 22.5%,
23%, 23.5%, 24%, 24.5%, 25%, 25.5%, 26%, 26.5%, 27%, 27.5%, 28%,
28.5%, 29%, 29.5%, 30%, 30.5%, 31%, 31.5%, 32%, 32.5%, 33%, 33.5%,
34%, 34.5%, 35%, 35.5%, 36%, 37%, 37.5%, 38%, 38.5%, 39%, 39.5%,
40%, 41%, 41.5%, 42%, 42,5%, 43%, 43.5%, 44%, 44.5%, 45% or any
range bounded by any two of the foregoing values). Dilute acid
hydrolysis is a simpler process, but is optimal at higher
temperatures (100.degree. C. to 230.degree. C.) and pressure.
Different kinds of acids, with concentrations in the range of
0.001% to 10% (e.g., 0.001%, 0.01%, 0.05%, 0.1%, 0.15%, 0.2%,
0.25%, 0.3%, 0.35%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%,
4%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5%, 8%, 8.5%, 9%, 9.5% or 10%, or any
range bounded by any two of the foregoing values) are preferably
used. Suitable acids including nitric acid, sulfurous acid, nitrous
acid, phosphoric acid, acetic acid, hydrochloric acid and sulfuric
acid can be used in the hydrolysis step. Preferably sulfuric acid
is used.
[0039] Depending on the acid concentration, and the temperature and
pressure under which the acid hydrolysis step is carried out,
corrosion resistant equipment and/or pressure tolerant equipment
may be needed.
[0040] The hydrolysis can be carried out for a time period ranging
from 2 minutes to 10 hours (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 15,
20, 25, 26, 27, 28, 29, or 30 minutes, or 0.5, 0.75, 1, 1.5, 2,
2.5, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5 or 10
hour, or range bounded by any two of the foregoing values),
preferably 1 minute to 2 hours, 2 minutes to 15 minutes, 2 minutes
to 2 hours, 15 minutes to 2 hours, 30 minutes to 2 hours, 10
minutes to 1.5 hours, or 1 hour to 5 hours.
[0041] The hydrolysis can also include, as an alternative (e.g., in
the absence of) or in addition to (e.g., before or after) the acid
treatment, a heat or pressure treatment or a combination of heat
and pressure, e.g., treatment with steam, for about 0.5 hours to
about 10 hours (e.g., 0.5, 1, 1.5, 2, 3, 3.5, 4, 4.5, 5.5, 6, 6.5,
7, 7.5, 8, 8.5, 9, 9.5 or 10 hours, or any range bounded by any two
of the foregoing values).
[0042] Variations of acid hydrolysis methods are known in the art
and are encompassed by the methods of the present disclosure. For
instance, the hydrolysis can be carried out by subjecting the
biomass material to a two-step process. The first (chemical)
hydrolysis step is carried out in an aqueous medium at a
temperature and a pressure chosen to effectuate primarily
depolymerization of hemicellulose without achieving significant
depolymerization of cellulose into glucose. This step yields slurry
in which the liquid aqueous phase contains dissolved
monosaccharides and soluble and insoluble oligomers of
hemicellulose resulting from depolymerization of hemicellulose, and
a solid phase containing cellulose and lignin. See, e.g., U.S. Pat.
No. 5,536,325. In a preferred embodiment, sulfuric acid is utilized
to affect the first hydrolysis step. After the sugars are separated
from the first-stage hydrolysis process, the second hydrolysis step
is run under harsher condition to hydrolyze the more resistant
cellulose fractions.
[0043] In another embodiment, the hydrolysis method entails
subjecting biomass material to a catalyst comprising a dilute
solution of a strong acid and a metal salt in a reactor. The
biomass material can, e.g., be a raw material or a dried material.
This type of hydrolysis can lower the activation energy, or the
temperature, of cellulose hydrolysis, ultimately allowing higher
yields of fermentable sugars. See, e.g., U.S. Pat. Nos. 6,660,506;
6,423,145.
[0044] A further exemplary method involves processing a biomass
material by one or more stages of dilute acid hydrolysis using
about 0.4% to about 2% of an acid; followed by treating the
unreacted solid lignocellulosic component of the acid hydrolyzed
material with alkaline delignification. See, e.g., U.S. Pat. No.
6,409,841. Another exemplary hydrolysis method comprises
prehydrolyzing biomass (e.g., lignocellulosic materials) in a
prehydrolysis reactor; adding an acidic liquid to the solid
lignocellulosic material to make a mixture; heating the mixture to
reaction temperature; maintaining reaction temperature for a period
of time sufficient to fractionate the lignocellulosic material into
a solubilized portion containing at least about 20% of the lignin
from the lignocellulosic material, and a solid fraction containing
cellulose; separating the solubilized portion from the solid
fraction, and removing the solubilized portion while at or near
reaction temperature; and recovering the solubilized portion.
[0045] Hydrolysis can also comprise contacting a biomass material
with stoichiometric amounts of sodium hydroxide and ammonium
hydroxide at a very low concentration. See Teixeira et al., 1999,
Appl. Biochem. and Biotech. 77-79:19-34. Hydrolysis can also
comprise contacting a lignocellulose with a chemical (e.g., a base,
such as sodium carbonate or potassium hydroxide) at a pH of about 9
to about 14 at moderate temperature, pressure, and pH. See PCT
Publication WO 2004/081185.
[0046] Ammonia hydrolysis can also be used. Such a hydrolysis
method comprises subjecting a biomass material to low ammonia
concentration under conditions of high solids. See, e.g., U.S.
Patent Publication No. 20070031918 and PCT publication WO
2006/110901.
[0047] Following hydrolysis, the hydrolyzed product comprises a
mixture of acid or base, partially degraded biomass and fermentable
sugars. Prior to further processing, the acid or base can be
removed from the mixture by applying a vacuum. The mixture can also
be neutralized prior to detoxification.
[0048] Prior to detoxification, the aqueous fraction comprising the
solubilized sugars can be separated from insoluble particulates
remaining in the mixture in a process referred to as solid/liquid
separation. Methods for separating the soluble from the insoluble
fractions include, but are not limited to, centrifugation
(continuous, semi-continuous and batch), decantation and
filtration. The hydrolyzed biomass solids can optionally be washed
with an aqueous solvent (e.g., water) to remove adsorbed
sugars.
[0049] The solids can be further processed prior to detoxification,
for example dewatered. Dewatering can be suitably achieved with a
screw press. The screw press is a machine that uses a large screw
to pull a stream containing solids along a horizontal screen tube.
Movement of the solids can be impeded by a weighted plate at the
end of the tube. The pressure of this plate on the solid plug
forces liquid out of the solids and through the holes in the sides
of the screen tube and then along the effluent pipe. The screw will
then push the remaining solids past the plate where they fall out
onto a collection pad or conveyor belt below.
Hydrolysate Characteristics
[0050] Following hydrolysis and of the biomass the solid/liquid
separation step, the lignocellulosic hydrolysate is subjected to
detoxification. The relative amounts and concentrations of the
individual compounds comprising the lignocellulosic hydrolysate
solution prior to detoxification (i.e., starting lignocellulosic
hydrolysate solution), including fermentable sugars, furan
aldehydes, aliphatic acids and phenolics, are dependent on the
particular lignocellulosic biomass and the hydrolysis method from
which the hydrolysate was obtained.
[0051] In certain embodiments, the starting hydrolysate solution
comprises (a) total fermentable sugars at a concentration ranging
from 30g/L to 160g/L , from 40 g/L to 95 g/L, or from 50 g/L to 70
g/L; (b) furfural at a concentration ranging from 0.5 g/L to 10
g/L, from 2.5 g/L to 4 g/L, or from 1.5 g/L to 5 g/L; (c) 5-HMF at
a concentration ranging from 0.1 g/L to 5 g/L, from 0.5 g/L to 2.5
g/L or from 1 g/L to 2 g/L (d) acetic acid at a concentration
ranging from 2 g/L to 17 g/L or from 11 g/L to 16 g/L; (e) lactic
acid at a concentration ranging from 0 g/L to 12 g/L or from 4 g/L
to 10 g/L; (f) additional aliphatic acids (e.g., succinic acid,
formic acid, butyric acid and levulinic acid) at concentrations
ranging from 0 g/L to 2.5 g/L; and /or (g) phenolics at a
concentration ranging from 0 g/L to 10 g/L, from 0.5 g/L to 5 g/L
or from 1 g/L to 3 g/L. In these embodiments, the starting
hydrolysate solution will be referred to herein as "1.times.".
[0052] In other embodiments, the starting hydrolysate can be more
concentrated than 1.times.. For example, the starting hydrolysate
solution can be 1.5-fold, 2-fold, 3-fold, 4-fold, 5-fold, 6-fold,
7-fold, 8-fold, 9-fold or 10-fold more concentrated than 1.times..
In these embodiments, the starting hydrolysate will be referred to
as 1.5.times., 2.times., 3.times., 4.times., 5.times., 6.times.,
7.times., 8.times., 9.times. and 10.times., respectively.
[0053] In other embodiments, the starting hydrolysate can be less
concentrated than 1.times.. For example, the starting hydrolysate
solution can be 0.1-fold, 0.2-fold, 0.3-fold, 0.4-fold, 0.5-fold,
0.6-fold, 0.7-fold, 0.8-fold or 0.9-fold as concentrated as
1.times.. In these embodiments, the starting hydrolysate will be
referred to as 0.1.times., 0.2.times., 0.3.times., 0.4.times.,
0.5.times., 0.6.times., 0.7.times., 0.8.times., and 0.9,
respectively.
[0054] The concentration of the hydrolysate solution can be
adjusted prior to the detoxification process. Concentration of the
hydrolysate solution can be particularly advantageous in the
context of a continuous process (see FIG. 1 and Section 4.4). For
example, a hydrolysate solution leaving a hydrolyzer following
dilute acidic hydrolysis and solid/liquid separation can be
concentrated prior to the addition of the magnesium base used for
detoxification. In certain embodiments, the hydrolysate solution
can be concentrated by 1.2-fold, 1.5-fold, 2-fold, 3-fold or 5-fold
prior to detoxification. In specific embodiments, the starting
hydrolysate can concentrated in a range bounded by any two of the
foregoing embodiments, e.g., concentrated by 1-fold to 3-fold,
1.5-fold to 3-fold, 3-fold to 5-fold, etc.
[0055] Concentrating the hydrolysate solution prior to
detoxification can result in increased selectivity for furan
aldehyde elimination over sugar degradation. Without being bound by
theory, it is believed that the rate of reaction is first order
with respect to sugar degradation and second order with respect to
furan aldehyde elimination. Accordingly, concentrating the
hydrolysate solution results in increasing the rate of elimination
of furan aldehydes relative to the rate of degradation of
fermentable sugars.
[0056] The hydrolysate solution can be concentrated under reduced
pressure and/or by applying heat. In one embodiment, the
hydrolysate solution is concentrated in a multi-stage evaporation
unit (see FIG. 1 and Example 1). Concentration of hydrolysate can
also be performed by other technologies such as membrane
filtration, carbon treatment and ion-exchange resin. Evaporation
results in increased sugar concentration and can result in the
removal of some amounts of furfural and acetate.
Detoxification of Hydrolysates with Magnesium Bases
[0057] The detoxification methods of the disclosure generally
entail mixing a lignocellulosic hydrolysate with a magnesium base
(e.g., magnesium hydroxide, magnesium carbonate or magnesium oxide)
for a period of time and under conditions that result in the
production of a detoxified lignocellulosic hydrolysate. The
detoxification methods are highly selective towards elimination of
furan aldehydes. As used herein, the phrase "highly selective
towards elimination of furan aldehydes" refers to the observation
that furan aldehydes react with magnesium bases at higher rates
than fermentable sugars react with magnesium bases. As a result,
the detoxified hydrolysates produced in accordance with the present
disclosure have a larger percentage of fermentable sugars and a
lower percentage of furan aldehydes relative to the starting
hydrolysate. The detoxified hydrolysates can then be fermented by a
suitable fermenting microorganism to produce a fermentation product
such as ethanol.
[0058] The detoxification methods typically comprise mixing a
starting lignocellulosic hydrolysate solution with a magnesium base
for a period of time and under conditions that result in the
production of a detoxified hydrolysate solution. The amount of time
suitable to perform the detoxification process depends on a number
of factors, including the chemical composition of the hydrolysate,
the concentration of the hydrolysate solution, the reaction
temperature, the pH of the hydrolysate solution, the total amount
of magnesium base added, the stirring rate, and the type of reactor
being used. The detoxification process is typically carried out for
a period of time ranging from 15 minutes to 80 hours, and more
typically between 1 hour and 40 hours. In specific embodiments, the
detoxification process is carried out for a period of time ranging
from 1 hour to 30 hours, from 1.5 hours to 20 hours, from 2 hours
to 12 hours, from 3 hours to 9 hours, from 4 hours to 10 hours, or
from 6 hours to 9 hours. This process is applicable for batch and
continuous vessel treatments.
[0059] The hydrolysate detoxification process is typically carried
out at a temperature of 90.degree. C. or less, for example at a
temperature of 30.degree. C., 35.degree. C., 40.degree. C.,
45.degree. C., 50.degree. C., 55.degree. C., 60.degree. C.,
70.degree. C., 75.degree. C., 80.degree. C. or 85.degree. C. In
specific embodiments, the temperature is in the range bounded by
any of the two foregoing embodiments, such as, but not limited to,
a temperature ranging from 40.degree. C. to 70.degree. C., from
40.degree. C. to 60.degree. C., from 40.degree. C. to 55.degree.
C., from 45.degree. C. to 55.degree. C., from 45.degree. C. to
50.degree. C., from 50.degree. C. to 55.degree. C., or from
40.degree. C. to 50.degree. C. In particular embodiments, the
temperature of the hydrolysate solution is in the range from
40.degree. C. to 60.degree. C. In this range, high selectivity for
furan aldehyde elimination is achieved while commercially feasible
rates of the detoxification reactions are observed.
[0060] The hydrolysate detoxification process is typically carried
out at a pH ranging from 6.2 to9.5, for example at a pH of 6.5, 7,
7.5, 8, 8.5, 9.0 or 9.5. In specific embodiments, the pH is in the
range bounded by any of the two foregoing values, such as, but not
limited to, a pH ranging from 6.5 to 8, from 6.5 to 7.5, from 7 to
8, or from 7 to 7.5. It will be understood that the pH of the
hydrolysate solution depends on the concentration of the magnesium
base and the temperature of the solution. In embodiments where
hydrolysate detoxification is carried out using magnesium
hydroxide, the solubility of the magnesium hydroxide decreases with
increasing temperature. Therefore, for a given amount of magnesium
hydroxide added to the hydrolysate solution, the equilibrium pH
decreases as the temperature is increased, all other variables
being constant (see, e.g., Table 3). The pH of the solution can
decrease slightly as the detoxification process progresses owing to
the consumption of hydroxide in reaction with sugars and furans.
Additional magnesium hydroxide can be added to the hydrolysate
solution to adjust the pH during the course of the reaction.
[0061] The total amount of magnesium base added to hydrolysate
solution 1.times. can range from 2 grams per 1 kilogram hydrolysate
(2 g/l kg hydrolysate) to 200 grams per 1 kilogram hydrolysate (200
g/l kg hydrolysate). For instance, the total amount of magnesium
base added to the hydrolysate solution can be 40 g/l kg
hydrolysate, 80 g/l kg hydrolysate, 100 g/l kg hydrolysate, 120 g/l
kg hydrolysate, 140 g/l kg hydrolysate, or 160 g/l kg hydrolysate.
The magnesium base can be added to the hydrolysate solution in a
single step, in multiple portions or continuously throughout the
course of the detoxification process. In specific embodiments, the
total amount of magnesium base added to the hydrolysate solution is
in the range bounded by any of the two foregoing embodiments, such
as, but not limited to, from 40 g/l kg hydrolysate to 160 g/l kg
hydrolysate, from 40 g/l kg hydrolysate to 120 g/l kg hydrolysate,
from 80 g/l kg hydrolysate to 160 g/l kg hydrolysate, from 80 g/l
kg hydrolysate to 140 g/l kg hydrolysate, or from 140 g/l kg
hydrolysate to 160 g/l kg hydrolysate. For more concentrated
hydrolysate solutions (e.g., 4.times.), the amount of magnesium
base sufficient to raise the pH to the desired level would be
increased relative to hydrolysate solution 1.times.. For less
concentrated hydrolysate solutions (e.g., 0.5.times.), the amount
of magnesium base sufficient to raise the pH to the desired level
would be decreased relative to hydrolysate solution 1.times..
[0062] The hydrolysate detoxification process can be performed in
any suitable vessel, such as a batch reactor or a continuous
reactor (e.g., a continuous stirred tank reactor (CSTR) or a plug
flow reactor (PFR). A continuous reactor allows for continuous
addition and removal of input materials (e.g., hydrolysate,
magnesium base slurry) as the detoxification reaction progresses.
The suitable vessel can be equipped with a means, such as
impellers, for agitating the hydrolysate solution. Reactor design
is discussed in Lin, K.-H., and Van Ness, H. C. (in Perry, R. H.
and Chilton, C. H. (eds), Chemical Engineer's Handbook, 5th Edition
(1973) Chapter 4, McGraw-Hill, NY.
[0063] The detoxification processes can be carried out in a batch
mode. The methods typically involve combining the hydrolysate
solution and the magnesium base (or magnesium base slurry) in the
reactor. The hydrolysate solution and the magnesium base can be fed
to the reactor together or separately. Any type of reactor can be
used for batch mode detoxification, which simply involves adding
material, carrying out the detoxification process at specified
conditions (e.g., temperature, dosage and time) and removing the
detoxified hydrolysate from the reactor.
[0064] Alternatively, the detoxification processes can be carried
out in a continuous mode. The continuous processes of the
disclosure advantageously reduces the need to stop and clean
reactors and accordingly can be carried out in continuous mode,
e.g., for periods of several days or longer (e.g., a week or more)
to support an overall continuous process. The methods typically
entail continuously feeding a hydrolysate solution and magnesium
base slurry to a reactor. The hydrolysate and the magnesium base
slurry can be fed together or separately. The resultant mixture has
a particular retention or residence time in the reactor. The
residence time is determined by the time to achieve the desired
level of detoxification following the addition of the hydrolysate
and the base to the reactor. Following the detoxification process,
the detoxified hydrolysate exits the reactor and additional
components (e.g., hydrolysate and base slurry) are added to the
reactor. Multiple such reactors can be connected in series to
support further pH adjustment during an extended retention time
and/or to adjust temperature during an extended retention time.
[0065] For detoxification in continuous mode, any reactor can be
used that allows equal input and output rates, e.g., a continuous
stirred tank reactor or plug flow reactor, so that a steady state
is achieved in the reactor and the fill level of the reactor
remains constant.
[0066] The detoxification processes of the disclosure can be
carried out in semicontinuous mode. Semicontinuous reactors, which
have unequal input and output streams that eventually require the
system to be reset to the starting condition, can be used.
[0067] The present disclosure provides methods of continuously
detoxifying a biomass obtained from a lignocellulosic biomass. As
depicted in FIG. 1, steps of the continuous detoxification process
include flowing a first continuous stream of a hydrolysate into a
continuous reactor, flowing a second continuous stream of a
solution of a magnesium base into the continuous reactor, mixing
the hydrolysate with the magnesium base in the continuous reactor
for a period of time sufficient to reduce the quantity of toxins in
the hydrolysate, and flowing the hydrolysate out of the continuous
reactor.
[0068] The methods of the disclosure can include farther steps in
addition to detoxification, such as one or more steps depicted in
FIG. 1 that are upstream or downstream of the detoxification step.
In FIG. 1, only steps that are downstream of biomass hydrolysis are
depicted. Following hydrolysis of the biomass and solid/liquid
separation, the hydrolysate is concentrated in a multistage
evaporation unit 100. The hydrolysate leaves the multi-stage
evaporation unit 100 through line 101 and enters continuous stirred
tank reactor 102. The hydrolysate can be heated prior to entering
continuous stirred tank reactor 102. Magnesium hydroxide is
supplied continuously to the continuous stirred tank reactor
through line 103. After the detoxification in continuous stirred
tank reactor 102 is complete, the detoxified hydrolysate is passed
into line 104, where it is met with a stream of acid (e.g.,
sulfuric acid or phosphoric acid) from line 105. The mixture of
detoxified hydrolysate is passed into mixer 106. The neutralized
detoxified hydrolysate exits mixer 106 through line 107 and flows
into fermentation vessel 108.
[0069] Adequate mixing of the hydrolysate solution following
addition of the magnesium base can improve the rate of dissolution
of the base and ensure that the pH remains substantially
homogeneous throughout the solution. For instance, ideal mixing
will avoid the formation of local pockets of higher pH, which can
result in lower selectivity for furan elimination. Mixing speeds of
between 100 revolutions per minute (rpm) and 1500 rpm can be used
to ensure sufficient mixing of the hydrolysate solution. For
instance, mixing speeds of 100 rpm, 200 rpm, 400 rpm, 800 rpm and
1500 rpm can be used. In specific embodiments, mixing is carried
out at speeds bounded by any two of the foregoing mixing speeds,
such as, but not limited to from 100 rpm to 200 rpm, from 100 rpm
to 400 rpm, from 200 rpm to 400 rpm, from 400 rpm to 800 rpm or
from 800 rpm to 1,500 rpm. In other embodiments, intermittent
mixing regimes can be used where the rate of mixing is varied as
the detoxification process progresses. Mixing of the hydrolysate
solution can be accomplished using any mixer known in the art, such
as a high-shear mixer, paddle mixer, magnetic stirrer or shaker,
vortex, agitation with beads, and overhead stirring.
[0070] The detoxification methods of the present disclosure provide
detoxified hydrolysates in which a substantial portion of the furan
aldehydes have been removed relative to the starting hydrolysate.
At the same time, the detoxification results in minimal loss of
fermentable sugars. Therefore, the detoxification reactions are
highly selective towards elimination of furan aldehydes. In
particular embodiments, methods disclosed herein provide a
detoxified hydrolysate with at least 70%, at least 80%, at least
85%, at least 90%, at least 95% or at least 99% of the fermentable
sugars present in the starting hydrolysate and no greater than 50%,
no greater than 40%, no greater than 30%, or no greater than 20% of
the furan aldehydes present in the staring hydrolysate
solution.
[0071] In particular embodiments, detoxification methods of the
present disclosure provide a detoxified hydrolysate with (a) at
least 90% of the total fermentable sugars present in the starting
hydrolysate and no greater than 50% of the furan aldehyde present
in the starting hydrolysate; (b) at least 90% of the total
fermentable sugars present in the starting hydrolysate and no
greater than 40% of the furan aldehydes present in the starting
hydrolysate; (c) at least 90% of the total fermentable sugars
present in the starting hydrolysate and no greater than 30% of the
furan aldehydes present in the starting hydrolysate; (d) at least
90% of the total fermentable sugars present in the starting
hydrolysate and no greater than 20% of the furan aldehydes present
in the starting hydrolysate; (e) at least 80% of the total
fermentable sugars present in the starting hydrolysate and no
greater than 50% of the furan aldehydes present in the starting
hydrolysate; (f) at least 80% of the total fermentable sugars
present in the starting hydrolysate and no greater than 40% of the
furan aldehydes present in the starting hydrolysate; (g) at least
80% of the total fermentable sugars present in the starting
hydrolysate and no greater than 30% of the furan aldehydes present
in the starting hydrolysate; (h) at least 80% of the total
fermentable sugars present in the starting hydrolysate and no
greater than 20% of the furan aldehydes present in the starting
hydrolysate.
[0072] In particular advantageous embodiments, the magnesium base
used for detoxification is magnesium hydroxide. An advantage of
magnesium hydroxide is that it effectively buffers the hydrolysate
solution as the detoxification process proceeds. Owing to the
limited solubility of magnesium hydroxide, the solid magnesium
hydroxide only dissociates further in a neutral or alkaline system
after the hydroxide ions react with the other components (e.g.,
furan aldehydes) comprising the hydrolysate. Furthermore, due to
the common ion effect, as hydroxide is consumed in reaction with
either furan aldehydes or sugars, the accumulation of soluble
magnesium ion (which does not react and is present as an observer
ion) would prevent further solubilization of magnesium hydroxide
and thus creates a limit on further pH increase. Therefore, the pH
of the solution remains within a narrow range throughout the course
of the detoxification process.
[0073] Without being bound by theory, it is believed that the high
selectivity towards elimination of furan aldehydes observed using
methods of the present disclosure stems in part from the tight pH
control achieved with magnesium hydroxide or magnesium carbonate as
a detoxification base. Titration studies indicate that magnesium
hydroxide has a low solubility in hydrolysate solutions,
particularly at a pH in the range of 6 to 8, where the
detoxification process is generally performed (see FIG. 3 and
Example 6). Therefore, the quantity of hydroxide ion in the
hydrolysate solution available to react with the components of the
hydrolysate (e.g., total fermentable sugars and furan aldehydes) is
limited. Kinetic studies (see Example 7) suggest that the
activation energy for furfural destruction is lower than that for
sugar degradation. Accordingly, the large majority of the hydroxide
present in solution is directed towards reactions with the furan
aldehydes rather than the total fermentable sugars.
[0074] After the detoxification process is complete, the pH of the
detoxified hydrolysate solution can be lowered by adding a suitable
acid (e.g., sulfuric acid or phosphoric acid) (see FIG. 1). The pH
can be adjusted to a level that is suitable for a fermenting
microorganism. Generally, the pH is adjusted to a value between 3.5
and 8, and more typically between a value of 4 and 7. After the pH
is adjusted to the desired level, the detoxified hydrolysate can be
transferred to a fermentation vessel.
Fermentation of Detoxified Hydrolysates
[0075] The fermentation of sugars to fermentation products can be
carried out by one or more appropriate fermenting microorganisms in
single or multistep fermentations. Fermenting microorganisms can be
wild type microorganisms or recombinant microorganisms, and include
Escherichia, Zymomonas, Saccharomyces, Candida, Pichia,
Streptomyces, Bacillus, Lactobacillus, and Clostridium.
Particularly suitable species of fermenting microorganisms include
Escherichia coli, Zymomonas mobilis, Bacillus stearothermophilus,
Saccharomyces cerevisiae, Clostridia thermocellum,
Thermoanaerobacterium saccharolyticum, and Pichia stipitis.
Genetically modified strains of E. coli or Zymomonas mobilis can be
used for ethanol production (see, e.g., Underwood et al, 2002,
Appl. Environ. Microbiol. 68:6263-6272 and US 2003/0162271 A1).
[0076] The fermentation can be carried out in a minimal media with
or without additional nutrients such as vitamins and corn steep
liquor (CSL). The fermentation can be carried out in any suitable
fermentation vessel known in the art. For instance, fermentation
can be carried out in an Erlenmeyer flask, Fleaker, DasGip
fedbatch-pro (DasGip technology), 2L BioFlo fermenter or 10L
fermenter (B. Braun Biotech) (see Example 7). The fermentation
process can be performed as a batch, fed-batch or as a continuous
process. The starting pH of the fermentation broth ranges from a
value of 3.5 to a value of 8, and more typically from a value of 4
to a value of 7. The fermentation is generally carried out at a
temperature between 20.degree. C. and 40.degree. C., and more
typically between 25.degree. C. and 35.degree. C. In particular
embodiments, the fermentation is carried out for a period of time
between 5 to 90 hours, 10 to 50 hours, or from 20 to 40 hours.
Recovery of Fermentation Products
[0077] Fermentation products can be recovered using various methods
known in the art. Products can be separated from other fermentation
components by centrifugation, filtration, microfiltration, and
nanofiltration. Products can be extracted by ion exchange, solvent
extraction, or electrodialysis. Flocculating agents can be used to
aid in product separation. As a specific example, bioproduced
ethanol can be isolated from the fermentation medium using methods
known in the art for ABE fermentations (see for example, Durre,
1998, Appl. Microbiol. Biotechnol. 49:639-648; Groot et al., 1992,
Process. Biochem. 27:61-75; and references therein). For example,
solids can be removed from the fermentation medium by
centrifugation, filtration, decantation, or the like.
[0078] After fermentation, the fermentation product, e.g., ethanol,
can be separated from the fermentation broth by any of the many
conventional techniques known to separate ethanol from aqueous
solutions. These methods include evaporation, distillation,
azeotropic distillation, solvent extraction, liquid-liquid
extraction, membrane separation, membrane evaporation, adsorption,
gas stripping, pervaporation, and the like.
EXAMPLES
Example 1
Hydrolysis of Lignocellulosic Biomasses
[0079] A lignocellulosic biomass (e.g., energy cane or sugar cane)
was harvested and sized using a forage chopper, inoculated with a
preparation of Lactobacillus bacteria and stored in agricultural
bags until use. Prior to dilute acid hydrolysis, the
lignocellulosic biomass was removed from bags and washed with
process water to remove organic acids and then dewatered with a
screw press. The biomass was then conveyed to a pressurized
reaction chamber (i.e., hydrolyzer) along with water and sulfuric
acid (0.2% to 3%). The liquid/solid ratio of the slurry was
minimized to maximize the dissolved sugar concentration in the
hydrolysate following hydrolysis. The retention time in the
hydrolyzer and the temperature of the hydrolyzer was dependent on
parameters of the biomass (e.g., moisture and glucan levels). In
general, the temperature of the hydrolyzer ranged from 120.degree.
C. to 180.degree. C. and the retention time ranged from 3 minutes
to 2 hours.
[0080] Following dilute-acid hydrolysis, the resultant hydrolyzer
slurry contained solubilized sugars as well as residual insoluble
fiber. The slurry was explosively decompressed and blown into a
cyclone unit to depressurize the slurry. The material was
reslurried with wash water and screw presses were used for
dewatering the slurry in order to wring out soluble sugars and
toxins. Three screw press steps with countercurrent washing were
used to dewater and wash the cake of inhibitors. Countercurrent
washing is defined as wash water flowing in the opposite direction
to the cake flow. The high-percent solids slurry was diluted to a
low percent solids slurry (<10% solids) and pumped to a screw
press. This dilution was performed with a fraction of recycled
liquids delivered by counter-current exchange from later screw
presses (defined as "pressate") as the system achieved
steady-state. Clean water was added at the final screw press step
along with the pressate to make the cake pumpable. The primary
liquid/solid separation step was repeated with two more screw
presses to remove toxins from the cake. The resulting high percent
solids cake was carried forward for simultaneous saccharification
and fermentation and the pressate from the first step was collected
for detoxification work.
[0081] The concentrations of the individual compounds (e.g.,
sugars, furans and aliphatic acids) in the starting hydrolysate
from several biomass sources following dilute acid hydrolysis and
solid/liquid separation are shown in Table 1.
TABLE-US-00001 TABLE 1 Composition of Starting Hydrolysates total
succinic lactic formic acetic butyric levulinic glucose xylose
Arabinose sugar 5-HMF Furfural acid acid acid acid acid acid Name
Source (g/L) (g/L) (g/L) (g/L) (g/L) (g/L) (g/L) (g/L) (g/L) (g/L)
(g/L) (g/L) DP 110105 Sugar 22.74 67.05 6.83 96.61 1.04 3.13 0.00
2.04 1.37 15.55 0.00 1.03 Cane DP 100309 Sorghum 14.4 42.55 7.00
63.95 0.36 2.05 0.22 10.92 0.53 11.53 0 ND DP 100511 Energy 11.01
46.6 6.25 63.86 0.33 1.7 0.00 6.85 0.43 9.83 0 0.49 Cane DP
100513-1 Energy 10.75 57.27 8.55 76.56 0.36 2.73 0.33 10.06 0.50
11.59 0.00 0.61 Cane DP 100513-2 Energy 15.1 54.2 7.95 77.25 0.42
2.97 0.064 12.00 0.66 14.34 0.00 0.61 Cane
Example 2
Detoxification of Hydrolysates with Magnesium Hydroxide--Batch
Reactor
5.2.1. Materials and Methods
[0082] 5.2.1.1. Sorghum Hydrolysate DP 100309
[0083] Hydrolysate DP 100309 was placed in a 1L three necked round
bottom flask equipped with stir bars. The round bottom flask was
placed in oil bath and heated to 70.degree. C. While the
hydrolysate solution was warming, target amounts of magnesium
hydroxide slurry (i.e., supersaturated solution of magnesium
hydroxide in water) were weighed. The total quantity of magnesium
hydroxide added to the hydrolysate was determined from the
titration of the hydrolysate solution with sodium hydroxide (see
FIG. 3 and Example 6). Also, see Martinez et al., 2001, Biotechnol.
Prog. 17(2):287-293. After the hydrolysate solution was heated to
the desired temperature, the magnesium hydroxide slurry was added
rapidly to the hydrolysate solution at a dosage of 22.86 g/Kg
hydrolysate at 70.degree. C. The solution was stirred vigorously
with a magnetic stirrer for 3 hours. The progress of the
detoxification process was monitored over time. Samples from the
hydrolysate solution at various time points were taken and quenched
with a stop solution (50 mM H.sub.2SO.sub.4) on ice (approximately
1.3 ml of each time point sample was immediately added to 11.7 ml
of ice cold stop solution (50 mM H.sub.2SO.sub.4, 10.times. fold
dilution) to quench any further reaction from occurring on the time
scale of further chemical analysis). After the detoxification
process was complete, the detoxified hydrolysate was then cooled to
the fermentation temperature, and pH was adjusted to fermentation
pH by adding 4M H.sub.2SO.sub.4.
[0084] Following acidification of the detoxified hydrolysate
solution, the concentrations of the individual compounds in the
hydrolysate were measured. Sugars were separated and quantified by
HPLC. A Shodex SP0810 size exclusion and ligand exchange column was
used with an Agilent 1200 series refractive index detector (RID).
An isocratic method was run using HPLC grade water as a mobile
phase which provides enough resolution to generate a chromatogram
from which the different sugar concentrations can be calculated,
including xylose, arabinose, glucose, cellobiose, galactose,
mannose, and other sugars.
[0085] Furfural and 5-HMF concentrations were also analyzed by HPLC
using an Alltech Platinum C18 column and the same Agilent RID.
Samples are diluted into a water/acetonitrile mixture and
transferred into vials or well plate. These samples are identified
and quantified by retention times and peak area against standard
curves against known concentrations of various analytes.
[0086] 5.2.1.2. Energy Cane Hydrolysate DP 100511
[0087] Hydrolysate DP 100511 was placed in a 1L three necked round
bottom flask equipped with stir bars. The round bottom flask was
placed in oil bath and heated to 70.degree. C. While the
hydrolysate solution was warming, target amounts of magnesium
hydroxide slurry were weighed. After the hydrolysate solution was
heated to the desired temperature, the magnesium hydroxide slurry
was added rapidly to the hydrolysate solution at a dosage of 16.53
g/Kg hydrolysate at 70.degree. C. The solution was stirred
vigorously with a magnetic stirrer for 3 hours. The progress of the
detoxification process was monitored over time. Samples from the
hydrolysate solution at various time points were taken and quenched
with a stop solution (50 mM H.sub.2SO.sub.4) on ice (approximately
1.3 ml of each time point sample was immediately added to 11.7 ml
of ice cold stop solution (50 mM H.sub.2SO.sub.4, 10.times. fold
dilution) to quench any further reaction from occurring on the time
scale of further chemical analysis). After the detoxification
process was complete, the detoxified hydrolysate was then cooled to
the fermentation temperature, and pH was adjusted to fermentation
pH by adding 4M H.sub.2SO.sub.4.
[0088] Following acidification of the detoxified hydrolysate
solution, the concentrations of the individual compounds in the
hydrolysate were measured as described in Section 5.2.1.1.
[0089] 5.2.1.3. Energy Cane Hydrolysate DP 100513-1
[0090] Hydrolysate DP 100513-1 was placed in a 1L three necked
round bottom flask equipped with stir bars. The round bottom flask
was placed in oil bath and heated to 70.degree. C. While the
hydrolysate solution was warming, target amounts of magnesium
hydroxide slurry were weighed. After the hydrolysate solution was
heated to the desired temperature, the magnesium hydroxide slurry
was added rapidly to the hydrolysate solution at a dosage of 22.59
g/Kg hydrolysate at 70.degree. C. The solution was stirred
vigorously with a magnetic stirrer for 10 hours. The progress of
the detoxification process was monitored over time. Samples from
the hydrolysate solution at various time points were taken and
quenched with a stop solution (50 mM H.sub.2SO.sub.4) on ice
(approximately 1.3 ml of each time point sample was immediately
added to 11.7 ml of ice cold stop solution (50 mM H.sub.2SO.sub.4,
10.times. fold dilution) to quench any further reaction from
occurring on the time scale of further chemical analysis). After
the detoxification process was complete, the detoxified hydrolysate
was then cooled to the fermentation temperature, and pH was
adjusted to fermentation pH by adding 4M H.sub.2SO.sub.4.
[0091] Following acidification of the detoxified hydrolysate
solution, the concentrations of the individual compounds in the
hydrolysate were measured as described in Section 5.2.1.1.
5.2.2. Results
[0092] 5.2.2.1. Selectivity of Biomass Detoxification of Various
Hydrolysates
[0093] Results for detoxification of lignocellulosic hydrolysates
obtained from sorghum (DP 100309) and energy cane (DP 100511 and DP
100513-1) carried out at either 50.degree. C. or 70.degree. C. are
shown in Table 2. The results shown in Table 2 indicate that
detoxification reactions have far greater selectivity for furan
aldehyde removal than for sugar loss. The percentage of sugar loss
at the indicated time point was 7% or less, while the percentage of
furan removal was 29.5% or greater. Hydrolysate solutions with a
higher initial concentration of furan aldehydes were mixed with the
magnesium hydroxide for longer times to achieve the desired level
of furan aldehyde elimination under a standard set of conditions.
For example, hydrolysate DP 100511, obtained from energy cane,
which had a starting concentration of 1.7 g/L furfural, was
detoxified for 3 hours at 70.degree. C. to achieve the desired
level of furfural elimination. On the other hand, hydrolysate DP
100513-1, also obtained from energy cane, which had a starting
concentration of 2.73 g/L furfural, was detoxified for 10 hours at
70.degree. C. to achieve the desired level of furfural
elimination.
[0094] The selectivity of the detoxification process is also
dependent on temperature. For instance, starting with hydrolysate
DP 100513-1, obtained from energy cane, negligible amounts of
sugars were lost after 9 hours when the detoxification process was
run at a temperature of 50.degree. C. At 70.degree. C., 5% of the
sugars were lost when the same hydrolysate was detoxified for 9
hours, all other conditions being the same. However, the percentage
of furfural removal for the detoxification process run at
70.degree. C. for 9 hours was more than twice that of the
detoxification at 50.degree. C. for nine hours. Hence, at lower
temperatures, longer reaction times provide acceptable levels of
furan elimination.
TABLE-US-00002 TABLE 2 Selectivity of Biomass Detoxification of
Different Hydrolysates Using Magnesium Hydroxide as a Base Grams of
pH Selectivity magnesium Initial Sugar Initial Furfural Reaction
Reaction following % % Final hydroxide/Kg of concentration
concentration temp Time Initial base sugar furfural furfural Name
Source Hydrolysate (g/L) (g/L) (.degree. C.) (h) pH addition loss
removal (g/L) DP 100309 sorghum 22.86 64 2.05 70 3 1.23 6.2 7 60.8
0.8 DP 100511 energy 16.53 64 1.7 70 3 1.48 6.1 4 40.9 1.04 cane DP
100513-1 energy 22.59 76.6 2.73 70 10 1.41 5.9 6.4 64.6 1.1 cane DP
100513-1 energy 22.59 76.6 2.73 50 9 1.2 5.7 0 29.5 1.89 cane DP
100513-1 energy 22.59 76.6 2.73 70 9 1.28 5.6 5 63.1 0.99 cane
[0095] 5.2.2.2. Detoxification of Hydrolysate Obtained from Energy
Cane at Varying Concentrations of Base and at Various
Temperatures
[0096] A hydrolysate obtained from energy cane (DP 100513-1) was
subjected to the detoxification procedure described above using
varying amounts of magnesium hydroxide at temperatures of
50.degree. C., 70.degree. C. and 90.degree. C. The concentrations
of the individual compounds of hydrolysate DP 100513-1 are shown in
Table 1. FIGS. 2A-2C provide graphs depicting the amount of xylose
and furfural elimination at various time points for detoxification
reactions using various dosages (i.e., 28.5 g magnesium hydroxide/1
kg hydrolysate, 85.5 g magnesium hydroxide/1 kg hydrolysate, and
142.5 g magnesium hydroxide/1 kg hydrolysate) performed at
50.degree. C., 70.degree. C. and 90.degree. C., respectively. At
50.degree. C. (FIG. 2A), the selectivity for furfural elimination
is high, irrespective of the concentration of magnesium hydroxide
used. The rate of furfural elimination increases with increasing
dosages of magnesium hydroxide. At a temperature of 70.degree. C.
(FIG. 2B), the selectivity for furfural elimination is still
significant, albeit less than the selectivity at 50.degree. C. The
rate of furfural elimination is slightly faster at 70.degree. C.
than at 50.degree. C. At 90.degree. C. (FIG. 2C), the selectivity
for furfural elimination is reduced relative to that of
detoxifications run at 50.degree. C. and 70.degree. C. and more
sugars are consumed in the process than detoxifications run at
lower temperatures. The rate of furfural elimination is
significantly greater at 90.degree. C. than at 50.degree. C. or at
70.degree. C.
Example 3
Detoxification of Hydrolysates--Series of CSTRS
[0097] The detoxification process is carried out using a series of
continuously stirred tank reactors (CSTRs). The hydrolysate
solution is heated to the target temperature with heating mantles
and/or recirculating water bath and delivered by peristaltic pump
to the first of a series of stirred reactors (1, 2, or 4L sizes)
connected in series to which magnesium hydroxide slurry is
previously added. The ratio of hydrolysate solution to magnesium
hydroxide slurry added to the reactor is based on titration dosage
(e.g., 1 ml/min of base slurry to 20 ml/min of hydrolysate). The
resultant mixture is then pumped to one or more additional CSTRs.
Additional base slurry is added to each successive CSTR reactor if
the pH of the mixture fell below a certain level. Retention time in
each reactor is constrained by fixing the target volume and
maintaining a target flow rate (where rate multiplied by volume
equals the retention time). To prevent build-up of foam, antifoam
is also delivered into one of the stirred tank reactors. The table
below describes operating planned operating ranges at laboratory
bench scale using two CSTR reactors in series.
TABLE-US-00003 Parameter Operating Ranges Hz pump rate 10-95 ml/min
Antifoam pump rate 0.1-0.5 ml/min Retention volume reactor 1
400-4000 ml Retention volume reactor 2 500-4000 ml Total retention
time 30-300 min Total base pump rate 0.1-20 ml/min Total output
flow rate 20-100 ml/min
Example 4
Relationship Between Temperature and PH in Hydrolysate
Detoxification with Magnesium Hydroxide
[0098] A hydrolysate obtained from energy cane (DP 100513-1) was
subjected to the detoxification procedure described in Section
5.2.1.3. using varying amounts of magnesium hydroxide at
temperatures of 50.degree. C., 70.degree. C. and 90.degree. C.,
respectively. Table 3 depicts the pH of the reaction as a function
of temperature of the hydrolysate following addition of 142.5
magnesium hydroxide/1 kg hydrolysate. As indicated in Table 3, the
pH of the hydrolysate solution decreases as the temperature of the
solution is increased.
TABLE-US-00004 TABLE 3 Effect of Temperature on pH in
Detoxification of Lignocellulosic Hydrolysates with Magnesium
Hydroxide Temperature Reaction Dosage (.degree. C.) Time (h) (g
Mg(OH).sub.2/kg hydrolysate) pH 50 4 142.5 7.73 70 4 142.5 7.24 90
4 142.5 6.87
Example 5
Fermentation of Detoxified Hydrolysates
5.5.1. Materials and Methods
[0099] Following the detoxification and acidification, the
hydrolysate solutions were fermented to produce ethanol.
Fermentations of detoxified hydrolysate were conducted using E.
coli as ethanologen at 35.degree. C. Fermentation was carried out
in minimal media with or without additional nutrient such as
vitamins and CSL at starting pH between 5.0 and 7.0 with or without
pH control.
[0100] Processes include fermentation by Erlenmeyer flask, Fleaker
(Spectrum Lab), DasGip fedbatch-pro (DasGip technology), 2L BioFlo
fermenter (New Brunswick), and 10L fermenter (B. Braun Biotech).
Batch and fed-batch fermentations were conducted in 2L and 10L
fermenters. E. coli inoculum cultures were grown in three steps.
Seed I and II media consist of 40 mM MES, 1.times. AM6 (0.5 g/L
sodium phosphate, 0.859 g/L urea), 1% CSL, and 60.79 g/L glucose. A
250 ml Erlenmeyer flask containing 100 ml medium was inoculated
with 100 .mu.l glycerol stock, and grown for 11 hours at 35.degree.
C. on a rotary shaker at 120 rpm (seed I). Seed II culture was
inoculated with 100 .mu.A of seed I culture, and grown for 11 hours
at 35.degree. C. on a rotary shaker at 120 rpm. Seed III culture
containing 1.times. AM6, 5g/L CSL, 50% detoxified hydro lysate
(v/v), and 0.6% yeast autolysate was inoculated with 5% seed II
culture in 2 L fermenter and grown at 35.degree. C. (pH of 7) with
agitation at 495 rpm for 10-11 hours until the ethanol
concentration reached 5 g/L. The main fermentation vessel
containing 95% (v/v) detoxified hydrolysate and 1.times. AM6 with
or without additional nutrient was inoculated with 5% (v/v) seed
III inoculum, and aerobic fermentation was carried out in both
batch and fed-batch modes at 35.degree. C. (pH of 7). During
fed-batch fermentation, detoxified hydrolysate and AM6 were fed at
various rates using a dissolved oxygen cascade control strategy by
agitation ramping profile to maintain dissolved oxygen during
feeding.
[0101] Ethanol concentrations from fermentation samples were
determined using gas chromatography (GC, Agilent 6890 series). In
particular, an Agilent system with a flame ionization detector and
a HP-Innowax column was used. The GC system settings include 1) an
HP-INNOWax polyethylene glycol capillary column (30 m.times.0.25
mm.times.0.25 .mu.m); 2) helium as carrier gas at 0.8 mL/min
constant flow; 3) oven program: 40.degree. C. (hold for 5.6min),
ramp 25.degree. C./min to 125.degree. C.; 4) injection: inlet
temperature 250.degree. C., injection volume 1 .mu.L with a split
ratio of 100:1. The compound 1-propanol was used as internal
standard and a multi-point standard curve was obtained to calculate
the final ethanol concentration for each sample. Samples were
diluted with methanol containing 0.2% 1-propanol as an internal
standard and injected into GC system after removal of precipitates.
Ethanol was identified by retention time and quantified by peak
area.
5.5.2. Results
[0102] The ability of the ethanologen to manufacture ethanol,
defined as fermentability, was assessed for detoxified hydrolysates
following detoxification with magnesium hydroxide or with calcium
hydroxide. Detoxification reactions with calcium hydroxide were run
under standard overliming conditions (55.degree. C. for 30 minutes)
in similar fashion to detoxification reactions described in Example
2.
[0103] The results for fermentability of the detoxified
hydrolysates are shown in Table 4. In Table 4, the fermentability
metric has been normalized to standard overliming conditions, where
a fermentability of 1 is defined as a condition that reaches the
same maximal ethanol concentration as the standard overliming
condition. As shown in Table 4, the hydrolysates detoxified with
magnesium hydroxide shows slightly lower fermentability in E. coli
compared to the overliming control. Accordingly, detoxification
with magnesium hydroxide produces hydrolysates that are readily
fermented by ethanologens, producing high yields of ethanol. The
quantity of ethanol produced is comparable to that of hydrolysates
that are detoxified with calcium hydroxide.
TABLE-US-00005 TABLE 4 Fermentability of Detoxified Hydrolysates
Ethanol Production Fermentability normalized to Max ethanol
Hydrolysate overliming rate (g Name Biomass Ethanologen condition
EtOH/L/hr) DP 100309 sorghum E. coli 0.88 0.9 (BD28512) DP 100511
energy cane E. coli 0.92 0.86 (BD28512) DP 100513-1 energy cane E.
coli 0.88 0.9 (BD28512)
Example 6
Generation of Titration Curves
5.6.1. Materials and Methods
[0104] Titration curves for the addition of three different bases
(magnesium hydroxide, calcium hydroxide and sodium hydroxide) added
to hydrolysate DP 110105, derived from sugar cane, were generated
to determine the amount of base that can be added to raise the pH
of the hydrolysate solution to a particular levels. To generate
titration curves, a pre-heated, pre-weighed quantity of hydrolysate
DP 110105, was treated with stirring with periodic additions of
aliquots of the labeled base or base slurry, and the pH after each
addition of base aliquot was recorded. The base additions were done
via manual pipette, buret, peristaltic pump, or a syringe pump to
either a beaker with stir bar pre-charged with hydrolysate or an
overhead stirred tank reactor pre-charged with hydrolysate. A plot
was created of these pH values with volume of base used as the
abscissa and the pH value as the ordinate.
5.6.2. Results
[0105] The titration curves of the three bases are shown in FIG. 3.
Addition of increasing amounts of magnesium hydroxide to the
hydrolysate solution resulted in a slow rise of the pH up to a
maximum pH of less than 8. Addition of calcium hydroxide or sodium
hydroxide resulted in a precipitous rise in pH as the base was
added.
[0106] For calcium hydroxide addition, the pH levels off at a value
greater than 10. The titration studies indicate that magnesium
hydroxide has a low solubility in the hydrolysate solution,
particularly at a pH in the range of 6 to 8, where the
detoxification process is performed. Therefore, the quantity of
hydroxide ion in the hydrolysate solution available to react with
the compounds of the hydrolysate (e.g., total fermentable sugars
and furan aldehydes) is limited when magnesium hydroxide is used as
a detoxification base, particularly when compared to calcium
hydroxide or sodium hydroxide.
Example 7
Kinetic Studies for Detoxification with Magnesium Hydroxide
5.7.1. Materials and Methods
[0107] To analyze the kinetics of the detoxification process, the
methods described in Example 2 using hydrolysate DP 100513 with
magnesium hydroxide as a detoxification base were run at various
temperatures, pH levels, and concentrations of the hydrolysate.
Samples were taken at time points after the addition of base or
base slurry and characterized for concentration of various
analytes. The time-dependent decreases in concentration of xylose
and furfural were selected to represent the broader competition
between furans and aldoses, as these two compounds were present in
the highest concentration in the starting hydrolysate and thus were
most amenable to good model fits. These data were fit to the
general form of the Arrhenius equation assuming power law kinetics
to solve for the pre-exponential factor, orders of reaction and
activation energies. The model process was an iterative
minimization of the sums of squares for the errors such that all
data could be fit to a single equation for each parameter. Various
nonlinear fitting software was used, including Excel SOLVER and
Athena. The activation energy for the furfural removal equation was
lower than that for xylose elimination, which is consistent with
the higher selectivity for furfural destruction at lower
temperatures observed.
5.7.2. Results
[0108] Results from the kinetic study indicate that the activation
energy of furfural elimination is lower than the activation energy
for xylose degradation. As a result, higher selectivity is achieved
at lower temperatures.
SPECIFIC EMBODIMENTS AND INCORPORATION BY REFERENCE
[0109] All publications, patents, patent applications and other
documents cited in this application are hereby incorporated by
reference in their entireties for all purposes to the same extent
as if each individual publication, patent, patent application or
other document were individually indicated to be incorporated by
reference for all purposes.
[0110] While various specific embodiments have been illustrated and
described, it will be appreciated that various changes can be made
without departing from the spirit and scope of the
invention(s).
* * * * *