U.S. patent application number 15/984576 was filed with the patent office on 2018-09-20 for conversion system for biomass.
The applicant listed for this patent is XYLECO, INC.. Invention is credited to Marshall Medoff.
Application Number | 20180265901 15/984576 |
Document ID | / |
Family ID | 38957670 |
Filed Date | 2018-09-20 |
United States Patent
Application |
20180265901 |
Kind Code |
A1 |
Medoff; Marshall |
September 20, 2018 |
CONVERSION SYSTEM FOR BIOMASS
Abstract
The efficient production of ethanol from low-cost biomass (e.g.,
corn, sugar beets, sugar cane, switchgrass and/or paper) has become
increasingly important in making ethanol competitive with gasoline
and decreasing the United States' dependence on foreign oil. For
example, to reduce the cost of transporting biomass to ethanol
production facilities, mobile systems for producing ethanol from
biomass are provided. Also provided are small-scale ethanol
production facilities. For example, instead of transporting biomass
to the production facility, the facility is transported to the
biomass or is located nearby the source of the biomass. The ethanol
production facilities or components thereof may be transported via
land, water, or air. Production of other products, such as
hydrocarbons, natural gas, hydrogen gas, plastics, polymers, and
proteins, can also be made by the methods and facilities. Any
product described herein can be made in finished form or
un-finished form and moved, e.g., to a fixed facility, e.g., fixed
production facility.
Inventors: |
Medoff; Marshall;
(Wakefield, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
XYLECO, INC. |
Wakefield |
MA |
US |
|
|
Family ID: |
38957670 |
Appl. No.: |
15/984576 |
Filed: |
May 21, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14481472 |
Sep 9, 2014 |
10000778 |
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15984576 |
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13759601 |
Feb 5, 2013 |
8852907 |
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14481472 |
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13657928 |
Oct 23, 2012 |
8399216 |
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13759601 |
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12374549 |
Jun 2, 2009 |
8318453 |
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PCT/US2007/074028 |
Jul 20, 2007 |
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13657928 |
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60832735 |
Jul 21, 2006 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C12P 7/64 20130101; Y02E
50/30 20130101; Y02E 50/10 20130101; Y02P 20/133 20151101; C12P
5/00 20130101; Y02W 30/40 20150501; C12P 19/34 20130101; C12P 7/14
20130101; C12P 7/10 20130101; C12P 5/023 20130101; C12P 7/06
20130101; C12P 21/00 20130101; C12P 13/001 20130101; C12P 33/00
20130101 |
International
Class: |
C12P 7/14 20060101
C12P007/14; C12P 7/10 20060101 C12P007/10; C12P 33/00 20060101
C12P033/00; C12P 5/02 20060101 C12P005/02; C12P 7/64 20060101
C12P007/64; C12P 13/00 20060101 C12P013/00; C12P 19/34 20060101
C12P019/34; C12P 21/00 20060101 C12P021/00; C12P 5/00 20060101
C12P005/00; C12P 7/06 20060101 C12P007/06 |
Claims
1. A method of producing a product from lignocellulose comprising:
(a) producing a pre-processed biomass by milling a lignocellulosic
biomass at a first site utilizing portable components of a system
for processing biomass, (b) transporting the pre-processed biomass
to a second site, and (c) producing sugars at the second site,
utilizing an enzyme.
2. The method of claim 1, wherein the portable components comprise
a mechanical treatment module and a fermenter, reactor or
converter.
3. The method of claim 1, wherein the lignocellulose is selected
from the group consisting of sugar cane, shrubs, grasses, corn
husks, bushes, lumber, wood waste, pulp, leaves, twigs, plant
cuttings, branches, trees, vines, agricultural waste, and mixtures
thereof.
4. The method of claim 1, wherein transporting is performed with a
nautical vessel.
5. The method of claim 4, wherein the nautical vessel is a boat, a
barge, a ship, a dock, a floating platform, a sea platform, or a
sea rig.
6. The method of claim 1, wherein transporting is performed with a
land vehicle.
7. The method of claim 6, wherein the land vehicle is a tractor
trailer or train.
8. The method of claim 1, wherein the transporting is performed by
a land vehicle and a water vehicle.
9. The method of claim 1, said mechanical treatment module is
selected from the group consisting of cutters, shearing devices,
and mills.
10. The method of claim 1, wherein the first site and second site
are spaced apart by a distance of about 25 miles or more.
11. The method of claim 1, wherein the first site and second site
are spaced apart by a distance of about 100 miles or more.
12. The method of claim 2, wherein producing sugars comprises
utilizing the fermenter to hydrolyze the lignocellulose.
13. The method of claim 12, further comprising utilizing the
fermenter to ferment the sugars obtained from hydrolysis.
14. The method of claim 1, wherein the enzyme comprises cellulase.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 14/481,472, filed Sep. 9, 2014, which
is a continuation of U.S. patent application Ser. No. 13/759,601,
filed Feb. 5, 2013, now issued as U.S. Pat. No. 8,852,907, granted
on Oct. 7, 2014, which is a continuation application of U.S. patent
application Ser. No. 13/657,928, filed Oct. 23, 2012, now issued as
U.S. Pat. No. 8,399,216, granted on Mar. 19, 2013, which is a
continuation application of U.S. patent application Ser. No.
12/374,549, filed Jun. 2, 2009, now issued as U.S. Pat. No.
8,318,453, granted on Nov. 27, 2012, which is a national stage
entry of PCT/US2007/74028, filed Jul. 20, 2007, which claims
priority from U.S. Provisional Patent Application No. 60/832,735,
filed on Jul. 21, 2006, the contents of which is incorporated
herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a system for producing
energy (e.g., ethanol, hydrocarbons, gasoline, methane, natural
gas, and biodiesel), electricity, nutrients (human and animal),
pharmaceuticals (human and veterinary) (e.g., medicines, and
drugs), fertilizer, or other co-products from biomass. In
particular, the invention relates to mobile, portable, and modular
facilities for producing energy (e.g., ethanol, hydrocarbons,
gasoline, methane, natural gas, and biodiesel), electricity,
nutrients (human and animal), pharmaceuticals (human and
veterinary) (e.g., medicines, drugs), fertilizer, or other
co-products, by fermentation or other process from biomass (e.g.,
crops, agricultural waste, and municipal solid waste).
BACKGROUND
[0003] Ethanol has a variety of uses, including as an industrial
chemical and solvent, fuel additive, and straight liquid fuel.
Ethanol is a clean burning fuel that can be produced from renewable
sources such as crops (e.g., corn, and sugar cane), wood waste,
agricultural waste, or other biomass. Ethanol not only reduces air
emissions, but it also improves engine performance. Also, as a
renewable fuel, ethanol reduces the United States' dependence on
foreign fossil fuels. Recently, ethanol production in the United
States has grown from 175 million gallons in 1980 to 3.4 billion
gallons in 2004. There are currently 101 ethanol production
facilities on-line in the U.S., and 30 more are under construction.
Therefore, the production of ethanol in coming years is expected to
increase.
[0004] The majority of ethanol made in the U.S. is derived from
corn; however, ethanol can also be produced from other crops high
in starches and sugars, such as grain sorghum, wheat, barley,
potatoes, sugar cane, or sugar beets. The production of ethanol
starts with breaking down the complex sugars (e.g., amylose,
cellulose) found in these plants into simpler fermentable sugars
(e.g., dextrose). This first step can be accomplished using
enzymes, acid, water, and/or heat. Once the simpler sugars are
obtained, yeast or other fermenting microorganisms are added to
covert the sugar to ethanol. The ethanol is then removed from the
fermentation by distillation. Water may be removed from the ethanol
by dehydration, and the ethanol may be denatured to make it unfit
for human consumption by adding a small amount of gasoline or other
alcohol (e.g., methanol).
[0005] The production of ethanol as a fuel supplement has many
benefits including boosting the economy, creating jobs, benefiting
agriculture, aiding rural economic development, providing energy
security and independence, reducing greenhouse gas emissions, and
reducing emissions of other pollutants including carbon monoxide,
particulate matter, oxides of nitrogen, and other ozone-forming
pollutants.
[0006] Joseph DePardo in an article entitled "Outlook for Biomass
Ethanol Production and Demand"
(www.eai.doe.gov/oiaf/analysispaper/biomass.html) has said that the
production of ethanol from corn is a mature technology that is not
likely to see significant reductions in production costs. He
hypothesizes that the ability to produce ethanol from other low
cost biomass will be important to making ethanol competitive as a
fuel additive. Therefore, a need remains for improving the
production of ethanol from crops as well as other biomass including
"non-virgin" biomass such as municipal solid waste.
SUMMARY OF THE INVENTION
[0007] The present invention provides for the production of energy
(e.g., ethanol, hydrocarbons, gasoline, natural gas, methane,
biodiesel, and hydrogen gas), electricity, plastics, polymers,
nutrients (human and animal), proteins, biomolecules,
pharmaceuticals (human and veterinary), fertilizer, or other
products from biomass using a mobile or portable production
facility or small-scale facility. The invention stems, at least in
part, from the recognition that it may be more efficient,
economical, and/or convenient to move the production facility or to
have a small-scale facility nearby rather than moving the biomass
used as the starting material in the process or the product such as
ethanol produced by the facility. In certain embodiments, the
inventive facilities allow the use of local supplies of biomass and
other materials needed in the process such as water, electricity,
natural gas, gasoline, and sewer. In the case of mobile facilities,
the site may include certain infrastructure (e.g., a foundation
(e.g., concrete slab)) for the facility, walls, roof, building,
piping, wiring, sewer lines, gas lines, and lighting). The
inventive facilities also allow for the use of biomass
traditionally not thought of as useful for producing energy (e.g.,
ethanol, hydrocarbons, gasoline, natural gas, methane, biodiesel,
and hydrogen gas), electricity, plastics, polymers, nutrients
(human and animal), proteins, biomolecules, pharmaceuticals (human
and veterinary), fertilizer, or other products, such as algae,
aquatic plants, agricultural waste, and human waste. The inventive
systems have personal, commercial, governmental, agricultural, and
military applications.
[0008] In one aspect, the invention provides mobile production
facilities for processing biomass to produce any of the desired
products described herein. The mobile facilities of the invention
are easily transported, or components of the facility are easily
transportable. Transporting the production facility or components
of the facility rather than the biomass starting material is
particularly useful and economical given that many of the crops
used to produce energy (e.g., bioethanol, gasoline, hydrogen,
natural gas) or other desired products are seasonal. Therefore, a
production facility only needs to be operational in the area when
crops or other biomass is available for processing. After the
processing is done, the facility or certain components of the
facility can travel to another area with biomass available for
conversion to a desired product. The inventive facilities or
components thereof may be transported by water, air, land, or any
combination thereof. The inventive facilities may include parts of
the facility or infrastructure that is not transportable or mobile.
For example, the inventive production facility or components
thereof may be transportable on a boat, barge, ship, or other
nautical vessel. Such facilities are particularly useful for
producing ethanol or other products from aquatic biomass such as
algae (e.g., Sargassum) or aquatic plants. These facilities are
also useful in traveling on a body of water to different areas with
biomass suitable for the production of the desired product (e.g.,
traveling on a river or on the ocean and docking at an area with
suitable biomass for processing). The portable facilities or
components thereof may also be transported on land. For example,
the facility may be transported by a car, a truck, tractor trailer,
and railroad car(s). Again, the land vehicle with the portable
facility can travel to areas with biomass suitable for the
production of the desired product. Finally, the facilities may be
transported by air. The facility may be transported by plane,
helicopter, and blimp. Air transportation of the facility allows
for the use of biomass typically too far away from production
facilities to be used. The facility may be on the plane, or the
facility or components may be dropped from a plane or delivered by
plane. The mobile facility is typically conveniently sized and
organized to provide for easy transportation of the facility and/or
its individual components. In the case of land transport, the
transportation vehicles are typically able to travel roads and
highways used by cars, trucks, and tractor trailers. In the case of
sea transport, the facility or components are typically carried by
a boat or barge which is moved by a boat. In the case of air
transport, the facility or components is sized to fit in a plane
(e.g., cargo plane) or helicopter.
[0009] The inventive mobile facilities or facilities constructed
from mobile components may include any or all of the following
apparatuses useful in producing the desired product (e.g.,
ethanol): pre-processing means for the biomass, mills, cookers,
cooling containers, holding containers, fermenters, distillation
apparatuses, columns, piping transfer containers, and mixing
containers. In certain embodiments, the different stages of the
production facilities are linked together efficiently so that a
user can easily transfer materials from one stage of the production
process to another. The facilities may also include any reagents
needed in the production process including yeast or other
microorganisms (including genetically engineered microorganisms),
enzymes (e.g., amylase, and cellulase), acids (e.g., sulfuric acid,
hydrochloric acid), bases (e.g., sodium hydroxide), chemical
reagents, water, salts, molecular sieves, and columns. In certain
embodiments, when ethanol is being produced, the facility includes
denaturants such as gasoline or other alcohols for denaturing the
ethanol. The inventive facilities can include all the necessary
equipment and reagents conveniently stored in the facility making
for easy use of the facility. In certain embodiments, the facility
produces enough ethanol or other energy source to supply the energy
needs of a factory, town, village, and island. In certain
embodiments, the ethanol production facility produces less than 5
million gallons of ethanol per year. The facility may also
optionally include any equipment mandated by international,
federal, state, or local law including, for example, safety
equipment necessary to prevent or handle spills, fires, or other
emergencies.
[0010] As will be appreciated by one of skill in this art, the
production facility may be assembled from various transportable
components. These components may include pre-processing means for
the biomass, mills, cookers, cooling containers, holding
containers, fermenters, distillation apparatuses, columns, piping
transfer containers, and mixing containers. In certain embodiments,
the component comprises a combination of two or more of any of the
above. The facility may include non-transportable components. These
components of an ethanol production facility are designed for easy
assembly of the working facility at the site. The components may be
pre-fabricated. The components may be interchangeable and may
provide for scalability of the facility. In certain cases, the
components system allows the facility to be easily assembled and
broken apart for ease of portability. The various components of the
facility may be brought to the site using any combination of
transport means (e.g., air, water, and land). In certain
embodiments, the components are brought to a site with certain
infrastructure which may include electricity, shelter, foundation,
sewer, water, and natural gas lines. All or some of the components
may be later disassembled and moved to a new site. In certain
embodiments, particular components and/or the infrastructure may
remain at the site to be optionally used again.
[0011] In some cases, the mobile production facility or components
thereof are disposable so that after it has served its purpose a
portion or all of the facility is abandoned temporarily or
permanently. In other embodiments, the facility or components
thereof are meant to be re-used and are therefore transported from
place to place with suitable biomass. The facility may be
completely self-sufficient requiring only the addition of biomass,
or the facility may require other materials or utilities such as
water, electricity, natural gas, gasoline, and sewer. For example,
the ethanol or other energy produced by the mobile facility may be
used to power a generator to supply electricity to the facility, or
the ethanol or other energy source may be burned to provide the
heat to break down the biomass in a cooker or to run a
distillation. The ethanol or other energy may also be used to power
the vehicle used to transport the facility or components
thereof.
[0012] In another aspect, the invention also provides small-scale
ethanol production facilities (e.g., producing less than 5 million
gallons of ethanol). In certain embodiments, the inventive
small-scale facilities produce less than 1 million gallons of
ethanol. These small-scale facilities may be portable or components
of the system may be portable as described above. These facilities
may include any or all of the following apparatuses useful in
producing bioethanol: pre-processing means for the biomass, mills,
cookers, cooling containers, holding containers, fermenters,
distillation apparatuses, columns, piping transfer containers, and
mixing containers. In certain embodiments, the different stages of
the production facilities are linked together efficiently so that a
user can easily transfer materials from one stage of the ethanol
production process to another. The facilities may also include any
reagents needed in the ethanol production process including yeast
or other microorganisms (including genetically engineered
microorganisms), enzymes (e.g., amylase, and cellulase), acids
(e.g., sulfuric acid, and hydrochloric acid), bases (e.g., sodium
hydroxide), water, salts, molecular sieves, gasoline or other
alcohols for denaturing the ethanol, and any other reagents. The
inventive facilities can, e.g., include all the necessary equipment
and reagents conveniently stored in the mobile facility making for
easy use of the facility. In certain embodiments, the facility
produces enough ethanol to supply the ethanol needs of a factory,
town, village, and island. In certain embodiments, the facility
produces less than 5 million gallons of ethanol per year. The
facility may also optionally include any equipment mandated by
international, federal, state, or local law including, for example,
safety equipment necessary to prevent or handle spills, fires, or
other emergencies. Other products as described herein may also be
produced by the small-scale production facilities.
[0013] The present invention also provides processes for producing
a desired product using an inventive facility. The process uses
biomass from a local area in an inventive production facility to
produce the desired product locally. The locally produced product
(e.g., ethanol, gasoline, natural gas, hydrogen gas, and
hydrocarbons) is then preferably used locally to avoid the cost of
the transporting both the biomass and the final product.
Preferably, a local water source is used in the production process.
Other reagents needed for the process may be provided by the
facility or provided locally. The waste or co-products from the
production process, e.g., the distillers grain, can be used locally
as a highly nutritious livestock feed or as a fertilizer. Other
waste products or co-products from the process such as
biomolecules, carbohydrates, protein, and polymers may also be
packaged, used, and/or sold.
[0014] The mobile component-based ethanol production facilities and
small-scale production facilities complement larger-scale ethanol
production facilities (i.e., facilities that produce over 10-20
million gallons of ethanol per year). In some cases, the inventive
facilities may eliminate the need for large-scale ethanol
production facilities in some areas. The portable nature of certain
systems works especially well given the cyclical nature of crops
and other biomass in various geographic areas. These inventive
facilities also allow for the economical production of ethanol from
low cost biomass, which will aid making ethanol a competitive fuel
additive. In certain embodiments, the inventive system uses biomass
that is not corn, sugarcane, or sugarbeet, or includes a small
portion of these crops.
[0015] In one aspect, the invention features a facility for
producing ethanol from biomass. Such a facility includes at least
one component that is portable.
[0016] In some embodiments, the component performs at least one
step in the process of converting biomass to ethanol. For example,
the component can pre-processes the biomass, ferment the biomass,
or purify ethanol produced from the biomass.
[0017] In some embodiments, the facility is capable of only
producing less than about 1 million gallons of ethanol per year, or
less than about 5 million gallons of ethanol per year.
[0018] In some instances, the facility includes at least two
portable components.
[0019] In another aspect, the invention features a portable
facility for producing ethanol from biomass.
[0020] In another aspect, the invention features a portable
facility for producing ethanol from biomass. Such a facility
includes a means for transporting the facility and a fermenter for
converting sugars derived from biomass into ethanol.
[0021] For example, the facility can be transported by land. For
example, the facility can be transported by railroad.
[0022] For example, the facility can be transported by water, such
as by using a boat, barge or other nautical vessel.
[0023] For example, the facility can be transported by air, such as
by using an airplane or helicopter.
[0024] For example, more than one mode of transportation can be
used. For example, any one or more of air, land or nautical modes
may be utilized. For example, train in combination with barge or
boat, or blimp in combination with train.
[0025] For example, the facility can further include a means for
converting complex sugars of biomass into simpler, more fermentable
sugars.
[0026] For example, the facility can also include a means for
purifying the ethanol produced in the fermenter, such as one or
more distillation columns.
[0027] In another aspect, the invention features a portable
facility for producing ethanol from biomass that includes a means
for transporting the facility, a mill for grinding the biomass, a
cooker for liquefying the biomass, a fermenter for converting
sugars derived from biomass into ethanol and a distillation
apparatus.
[0028] In another aspect, the invention features a method of
producing ethanol from biomass that includes providing biomass;
providing a portable ethanol production facility; and producing
ethanol from the biomass using the portable ethanol production
facility.
[0029] In another aspect, the invention features methods of
producing ethanol from biomass, e.g., one or more cellulosic and/or
lignocellulosic materials (e.g., switchgrass and/or paper), that
include producing ethanol from biomass at a first site with a
reactor or a converter, e.g., a fermenter; transporting the reactor
or converter to a second site; and producing ethanol from biomass
at the second site with the reactor or converter.
[0030] For example, the biomass can be or can include any
cellulosic or lignocellulosic material, such as corn, sugar cane,
sugar beets, trees, shrubs, grasses, phytoplankton, zooplankton,
algae, macroalgae, seaweed, corn husks, bushes, lumber, wood waste,
pulp, cotton, wool, linen, paper, newspapers, corrugated
containers, mixed paper, computer printouts, white office paper,
printing plant scraps, leaves, twigs, grass, plant cuttings,
branches, trees, vines, sewage, agricultural waste. Mixtures of any
of these can also be utilized.
[0031] For example, transporting can be performed with a nautical
vessel, e.g., a boat, a barge, a ship, dock or a floating platform.
For example, transporting can be performed with a land vehicle,
such as a car, truck, tractor trailer or train. For example,
transporting can be performed with an airborne vehicle, such as a
plane, helicopter or blimp.
[0032] In some embodiments, transporting is performed by more than
a single mode, such as by a land vehicle and a water vehicle.
[0033] In some embodiments, the producing is performed while
transporting.
[0034] In some embodiments, the system uses fixed resources, such
as piping and/or electricity a given site.
[0035] In some embodiments, the reactor or converter forms part of
a system and the system also includes a component such as cutters,
shearing devices, measuring devices, flow devices, mills, mixers,
pumps, wiring, cookers, heaters, coolers, aerators, containers,
holding containers, distillation columns, piping, or mixtures of
these.
[0036] Spacing between a first site and a second site can be small
or relatively large. For example, the sites can be physically
beside one another. For example, the ethanol can be produced while
the system is being carried by a moving train.
[0037] In other embodiments, the first site and second site are
spaced apart by a distance of about 25 miles or more, e.g., about
50 miles or more, about 75 miles or more, about 100 miles or more,
about 150 miles or more, about 250 or more miles, or even about 500
miles or more.
[0038] In some embodiments, producing ethanol from biomass at the
first and/or second site includes hydrolyzing the biomass, and then
fermenting the biomass.
[0039] The methods can further include, e.g., transporting the
system to a third site, and then producing ethanol at the third
site. The methods can include also a fourth, fifth, sixth, seventh,
eighth or more sites. Producing can occur at any number of these
sites.
[0040] In some embodiments, prior to producing ethanol from biomass
at the first and/or second site with the system, the system is
assembled.
[0041] For example, the producing ethanol from biomass can include
contacting the biomass with one or more microorganisms, such as a
one or more species of yeast and/or bacteria, disposed in the
fermenter. Combinations of different organisms may be used, e.g.,
combinations of yeast and bacteria or different species of yeast or
bacteria.
[0042] For example, the one or more microorganisms can include one
or more genetically engineered bacteria.
[0043] In another aspect, the invention features methods of
producing energy from biomass that include producing a first energy
source from biomass at a first site with a reactor or a converter;
transporting the reactor or a converter to a second site; and
producing a second energy source from biomass at the second site
with the reactor or a converter.
[0044] In some embodiments, the first and second energy sources are
the same.
[0045] For example, the energy source can be an alcohol, such as
ethanol or n-butanol, gasoline, hydrocarbons, hydrogen, natural
gas, biodiesel, electricity or mixtures of any of these.
[0046] In specific embodiments, the energy source is or includes an
alcohol, such as ethanol.
[0047] In another aspect, the invention features methods of
producing products from biomass that include producing a first
product from biomass at a first site with a reactor or a converter;
transporting the system to a second site; and producing a second
product from biomass at the second site with the reactor or a
converter.
[0048] In some embodiments, product of products can be made in a
mobile facility, and then finished in a fixed facility, e.g., fixed
production facility. For example, the un-finished product or
products can be transported by a vehicle, e.g., a train and/or a
ship, or another conveyance method, such as pipes. Combinations of
these conveyance methods can be utilized.
[0049] In some embodiments, the first and second products are the
same.
[0050] In some embodiments, the first or second products include
ethanol and/or n-butanol.
[0051] For example, product can be ethanol, n-butanol,
hydrocarbons, gasoline, natural gas, methane, biodiesel, hydrogen,
electricity, polymers, nutrients, proteins, biomolecules,
pharmaceuticals, pharmaceutical products, fertilizer or mixtures of
any of these.
[0052] In some embodiments, the first or second products include
one or more biomolecules. For example, the biomolecule can be a
nucleic acid, a protein, a lipid, a steroid, a natural product, a
metabolic product, a nucleotide, a fat, an amino acid, a peptide or
mixtures of any of these.
[0053] In another aspect, the invention features methods of
producing products from biomass, e.g., cellulosic or
lignocellulosic materials, the include producing a first product
from biomass at a first site with a reactor, the first site being
located on a body of water; transporting the reactor to a second
site also on the body of water; and producing a second product from
biomass at the second site with the reactor. In such aspects, the
biomass can be obtained from the body of water.
[0054] For example, the biomass can be plankton, aquatic plants,
algae, seaweed or mixtures of these.
[0055] In another aspect, the invention features methods of
producing products from biomass that include producing a first
product from biomass at a first site with a reactor or converter;
transporting the reactor or converter by a first mode to a second
site; producing a second product from biomass at the second site
with the reactor or converter; and transporting the reactor or
converter by a second mode different than the first mode to a third
site.
Definitions
[0056] "Bioethanol": The term "bioethanol" refers to ethanol
produced partially or entirely from biomass. In certain
embodiments, bioethanol is produced by fermentation of sugars
derived from biomass. The term bioethanol is used interchangeably
herein with the term ethanol.
[0057] "Biomass": The term "biomass" refers to any material or
combination of materials that can be used in the production system
to produce energy (e.g., ethanol, hydrocarbons, gasoline, natural
gas, methane, biodiesel, and hydrogen gas), electricity, plastics,
polymers, nutrients (human and animal), proteins, biomolecules,
pharmaceuticals (human and veterinary; e.g., drugs and medicines),
fertilizer, or other products. In certain embodiments, sugars or
other organic compounds from the biomass are converted into ethanol
(e.g., by fermentation). Exemplary biomass includes crops (e.g.,
corn, sugar cane, sugar beets), trees, shrubs, grasses, plankton
(e.g., phytoplankton, zooplankton, bacterioplankton), algae,
macroalgae (e.g., species from the genus Sargassum), seaweed,
agricultural waste (e.g., branches, corn husks, bushes, and weeds),
synthetic materials, synthetic plastics, industrial waste, recycled
waster, municipal solid waste, synthetic waste, human waste, animal
waste, commercial organics (e.g., beverage industry waste, cheese,
whey, dairy waste, food processing waste, lumber and industrial
wood waste, pulp and paper facility waste, restaurant waste,
fabrics, cotton, wool, and linen), construction and demolition
debris, waste paper (e.g., old newspapers, old corrugated
containers, mixed paper, pulp substitutes, computer printouts,
white office paper, and printing plant scraps), yard waste (e.g.,
leaves, twigs, grass, plant cuttings, branches, trees, and vines).
Biomass includes both virgin biomass and non-virgin biomass.
[0058] "Biomolecule": The term "biomolecule" refers to any chemical
compound that can be produced by a cell or organism. In certain
embodiments, the cell is wild type and has not been genetically
engineered by the hand of man. In other embodiments, the cell has
been altered by the hand of man. Exemplary biomolecules include
nucleic acids, proteins, lipids, steroids, natural products,
metabolic products, nucleotides, nucleosides, fats, amino acids,
and peptides.
[0059] "Components": The term "component" refers to any part of a
biomass conversion facility. The component may be of any size or
shape. It may include one or multiple pieces of equipment used in
the energy production or biomass conversion process. In certain
embodiments, the component includes several pieces of equipment. It
may optionally include piping or wiring and may optionally include
hookups so that it can be connected with other components or
infrastructure at the site. In certain embodiments, the component
is transportable by air, water, or land. Exemplary components
comprise one or more of the following: pre-processing means for the
biomass, mills, mixers, pumps, wiring, cookers, heating means,
cooling means, aeration means, cooling containers, holding
containers, fermenters, distillation apparatuses, columns, piping,
transfer containers, and mixing containers. In certain embodiments,
the components are for the modular assembly of an ethanol
production facility.
[0060] "Dehydration": The term "dehydration" refers to removing
water from a material. In certain embodiments, dehydration refers
to removing water from the ethanol produced by the system. The
resulting ethanol may be free of ethanol, or 1, 2, 3, 4, or 5%
water may remain in the ethanol. In certain embodiments, the
ethanol after dehydration includes less than 1% water. The ethanol
may be dehydrated using any means known in the art including
distillation, azeotroping, or using molecular sieves.
[0061] "Denatured ethanol": The term "denatured alcohol" refers to
ethanol that has been mixed with another material to make it unfit
for human consumption. In most jurisdictions, the sale of ethanol,
as a pure substance or in the form of alcoholic beverages, is
heavily taxed. In order to relieve non-beverage industries of this
tax burden, governments specify formulations for denatured alcohol,
which consists of ethanol blended with various additives to render
it unfit for human consumption. These additives, also known as
denaturants, are either toxic and/or have an unpleasant taste or
odor. Denatured ethanol formulations intended for a particular use
(e.g., use as a fuel additive) contain denaturants chosen so as not
to interfere with that use.
[0062] "Distillation": The term "distillation" refers to a process
of purifying the ethanol from the fermented mash. The distillation
process typically involves a change of state from a liquid to a gas
and subsequent condensation as a means of purification.
[0063] "Energy": The term "energy" includes any energy source that
can be produced from biomass. The energy produced from biomass is
typically organic compounds. The energy can be burned to produce
heat which can be used to produce electricity or power a vehicle
for example. In certain embodiments, the energy is ethanol. In
other embodiments, the energy is alcohol. In other embodiments, the
energy is hydrocarbons. In certain embodiments, the energy is fats.
In certain embodiments, the energy is fatty acids. In other
embodiments, the energy is acetic acid. In other embodiments, the
energy is gasoline. In certain embodiments, the energy is a mixture
of organic compounds. In certain embodiments, the energy is natural
gas. In certain embodiments, the energy is hydrogen gas. In certain
embodiments, the energy is methane gas. In certain embodiments, the
energy is biodiesel. In certain embodiments, the energy is
electricity.
[0064] "Ethanol": The term "ethanol" refers to the chemical
compound, CH.sub.3CH.sub.2OH. Ethanol is also referred to as grain
alcohol. Ethanol is a flammable, tasteless, colorless, mildly toxic
chemical compounds with a distinctive odor. The term ethanol may
refer to any degree of purity of ethanol. In certain embodiments,
the ethanol is at least 50%, 60%, 70%, 80%, 90%, 95%, 98%, or 99%
pure. In some cases, the ethanol is 100% pure. In other cases, the
ethanol is denatured with 1-10% or 2-5% other solvents (e.g.,
methanol, isopropanol, gasoline, hexanes, pentane) to make it unfit
for human consumption. In certain embodiments, the ethanol is mixed
with water. In other embodiments, the ethanol is anhydrous (e.g.,
after a dehydration step).
[0065] "Fermentation": The term "fermentation" refers to the
process of converting sugars to ethanol or any other desired
products including energy (e.g., hydrocarbons, gasoline, natural
gas, methane, biodiesel, and hydrogen gas), electricity, plastics,
polymers, nutrients (human and animal), proteins, biomolecules,
pharmaceuticals (human and veterinary; e.g., drugs and medicines),
and fertilizer. In certain embodiments, the term fermentation
refers to the process of making organic molecules useful as an
energy source from biomass. Fermentation is typically performed by
microorganisms such as bacteria or yeast. The fermentation process
for ethanol is typically performed in an oxygen-deficient
atmosphere to prevent the further oxidation of the desired ethanol
to acetic acid.
[0066] As defined herein, a "fermentor, reactor or a converter" is
a device that is capable of holding at least about 1,000 gallons of
material, such as a cellulosic and/or lignocellulosic material, a
microorganism and a solvent, such as water. In some embodiments,
the fermenter, reactor or converter is capable of holding greater
than about 2,000 gallons of material, greater than about 2,500
gallons, greater than about 5,000 gallons, greater than about
10,000 gallons, greater than about 25,000 gallons, greater than
about 50,000 gallons, or even greater than about 100,000
gallons.
[0067] All publications, patent applications, patents, and other
references mentioned herein are incorporated by reference in their
entirety for all that they contain.
[0068] Other features and advantages of the invention will be
apparent from the following detailed description, and from the
claims.
DESCRIPTION OF DRAWINGS
[0069] FIG. 1 is a block diagram that schematically illustrates
methods of producing various products, such as ethanol or
n-butanol.
[0070] FIG. 2 is a cross-sectional view of a rotary knife
cutter.
DETAILED DESCRIPTION
[0071] Described herein are mobile and/or small-scale (e.g., less
than 1-5 million gallons per year) systems for producing energy
(e.g., ethanol, hydrocarbons, gasoline, natural gas, methane,
biodiesel, and hydrogen gas), electricity, plastics, polymers,
nutrients (human and animal), proteins, biomolecules,
pharmaceuticals (human and veterinary; e.g., drugs and medicines),
fertilizer, or other products including processes, facilities, and
components of the facility for producing the desired product, from
biomass. The systems eliminate or at least reduce the need for
transporting the starting material biomass, which can be, e.g., of
a low bulk density, to a stationary large-scale production
facility. It also may reduce the need to transport the desired
product produced by the mobile facility a long distance to its end
user or a distribution facility. The system for producing the
desired product allows for the processing of biomass that
ordinarily would not be economically suitable for conversion to
energy (e.g., ethanol, hydrocarbons, gasoline, natural gas,
methane, biodiesel, and hydrogen gas), electricity, plastics,
polymers, nutrients (human and animal), proteins, biomolecules,
pharmaceuticals (human and veterinary; e.g., drugs and medicines),
fertilizer, or other products due to transportation, processing, or
other costs. The system makes the production of energy (e.g.,
ethanol, hydrocarbons, gasoline, natural gas, methane, biodiesel,
and hydrogen gas), electricity, plastics, polymers, nutrients
(human and animal), proteins, biomolecules, pharmaceuticals (human
and veterinary; e.g., drugs and medicines), fertilizer, or other
products more economical by reducing the costs, particularly the
transportation costs, of producing the desired product.
[0072] Production facilities that are configured in such a way that
it or its various components can be easily transported by land,
sea, air, or a combination thereof. In certain embodiments, the
materials and equipment need to produce desired product from
biomass are compactly organized so that it or its components can be
transported by a car, truck, tractor trailer, railroad, boat,
barge, airplane, helicopter, or combination thereof. In certain
embodiments, the facility or its components may be limited in size
depending on how the facility or its components are transported.
For example, a facility or component being transported by tractor
trailer will need to fit on the bed of a truck or trailer for
transport.
[0073] Referring to FIG. 1, methods of producing products, such as
ethanol or n-butanol, from biomass, e.g., cellulosic or
lignocellulosic material, include producing a first product at a
first site with a system that includes a reactor or converter,
e.g., a fermenter. The system is transported to a second site, and
then a second product is produced from biomass at the second site
with the system.
[0074] Any number of sites may be utilized. For example, the number
of sites can be 2, 3, 4, 5, 6, or more, e.g., 10, 20, 30, 50, 100
or more, e.g., 1000.
[0075] For example, a site may form part of a complex or a campus,
and portions of the complex or campus may be joined by various
manufacturing infrastructure, such as rail.
[0076] Spacing between a first site and a second site can be
relatively small or relatively large. For example, the sites can be
physically beside each other. For example, the system can be
carried by a moving train and producing ethanol while moving.
[0077] In other embodiments, the first site and second site are
spaced apart by a distance of about 10 miles or more, e.g., about
25 miles or more, about 35 or more, about 65 miles or more, about
85 miles or more, about 100 or more, about 200 miles or more, about
300 or more, or even about 500 miles or more.
[0078] In some embodiments, the fermentor, reactor or converter can
hold between about 1,000 gallons and about 100,000 gallons of
material, e.g., between about 2,500 gallons and about 100,000
gallons, or between about 5,000 gallons and about 75,000
gallons.
[0079] In certain embodiments, the mobile systems or one or more of
its components for producing the desired product is transported by
land. When the mobile facility or its components is transported by
roads, it preferably complies with all applicable laws governing
the roads of that country, state, province, county, or city. In the
U.S., facilities transported by land using highways and roads may
comply with all federal, state, and local laws and regulations. In
certain embodiments, the mobile facility being transported by a
tractor trailer is no larger than 8 feet 6 inches wide and no
longer than 57 feet in length. In certain embodiments, the facility
is no wider than 8 feet 6 inches and no longer than 53 feet. In
certain embodiments, the facility is no wider than 8 feet 6 inches
and no longer than 48 feet. In certain embodiments, the facility is
no wider than 8 feet 6 inches and no longer than 20-24 feet in
length. The height of the vehicle may vary depending on the
obstacles on the road the facility is being transported via.
However, typically the facility is less than 15 feet in height. In
certain embodiments, it is less than 14 feet in height. In certain
embodiments, the facility is transported by a double tractor
trailer in which case the total length for the combination is no
greater than 75 feet. In certain embodiments, the total length of
the double is no greater than 65 feet. In certain embodiments, the
gross combination weight of the vehicle with the mobile facility or
one or more of its component(s) is no greater than 80,000 pounds.
In certain embodiments, the facility or a component thereof fits
into a standard container used for shipping by tractor trailer. As
would be appreciated by one of skill in this art, the components of
the facility may be transported by more than one land vehicle or
may be transported by a land vehicle and a combination of land,
water, and air vehicles. In certain embodiments, components that
are not suitable for transport by water or air are transported by
land. In certain embodiments, components for which water and/or air
transportation are not economical are transported by land. However,
it is appreciated that in certain embodiments land transportation
of the facility or its components is not feasible or is not
possible (e.g., due to lack of passable roads).
[0080] In certain embodiments, the mobile production facility or
some of its components are small enough to be transported by a car,
sport utility vehicle (SUV), or pickup truck. In certain
embodiments, the facility or its components are transported on a
trailer pulled by a car, SUV, or pickup truck.
[0081] The mobile facility or its various components can also
transportable by railroad. In certain embodiments, the facility to
be transported by rail is no wider than 14 feet. In other
embodiments, the facility is no wider than 13 feet 6 inches. In
still other embodiments, the facility is no wider than 13 feet. In
certain embodiments, the facility is no wider than 12 feet 6
inches. The width clearance of the facility including its outer
container will depend on the railways being used to transport the
facility. In certain embodiments, the minimum width of 12 feet 6
inches or 13 feet is used to accommodate all railways the facility
could possibly travel along. The length of the facility is no
longer than 60 feet. In embodiments, the length of the facility is
less than 60 feet. In certain embodiments, the length is
approximately 58 feet. In other embodiments, the length is
approximately 59 feet, approximately 57 feet, or approximately 56
feet. The height of the facility is typically less than 23 feet. In
certain embodiments, the height is less than 22 feet. In other
embodiments, the height is less than 21 feet. In certain
embodiments, the height is less than 20 feet. In certain
embodiments, the facility or a component thereof fits into a
standard container used for shipping by railroad. In yet other
embodiments, the height is less than 19 feet. The weight of the
facility typically does not exceed 200,000 pounds. In certain
embodiments, when a larger mobile production facility is needed,
the facility is transported using more than one railroad car where
each railroad car includes a component. These components are then
assembled into an operational facility at the desired site. In
certain embodiments, the facility is assembled on a rail road
track, set of tracks, or spur. In certain embodiments, the facility
comprises 1-10 railroad cars. In certain embodiments, the facility
comprises 1-5 railroad cars. In certain embodiments, each step or a
combination of steps of the process of producing ethanol is
performed in a separate car. In certain embodiments, the equipment
for performing one or more steps is combined into one car. Various
components of the facility may also be brought to the site for
assembly by other land transportation, air transportation, or water
transportation.
[0082] Any combination of transporting modes can be utilized. For
example, the systems can be transported by land, and then by water,
or by air and then by land.
[0083] For example, the products such as ethanol can be produced
during transportation or after transportation.
[0084] When the facility or its components are transported by
water, the facility is optionally within the allowed limits of the
vessel transporting the facility or component(s). These limits
include length, width, height, and weight limits of the vessel
transporting the facility. As will be appreciated by one of skill
in this art, the size of the facility will greatly depend on the
size of the vessel transporting the facility or its component(s).
Larger ships and barges can transport a much larger ethanol
production facilities than smaller boats. When the facility or its
component(s) are transported by water, the facility may be
assembled on a barge, dock, wharf, platform, derek, rig, sand bar,
and island. In certain embodiments, the facility or a component
thereof fits into a standard container used for shipping by water.
In certain embodiments, the facility is assembled on a flotation
device. Various components of the facility may be brought to the
site for the facility by land or air as well as by water.
Facilities on the water or close to the water facilitate the use of
aquatic biomass such as plankton, algae, and aquatic plants in the
production of the desired product.
[0085] Similarly, when the facility is transported by air, the
facility or its component(s) are optionally within the allowed
limits of the aircraft transporting the facility. These limits
include length, width, height, and weight limits of the aircraft
transporting the facility. In certain embodiments, the aircraft is
an airplane. The airplane may be a propeller driven plane, a jet, a
cargo plane, a military plane, and a commercial airliner. In
certain embodiments, the aircraft is a helicopter. In certain
embodiments, the aircraft will transport the facility or the
component(s) hanging from the aircraft. In certain embodiments, the
facility or a component thereof fits into a standard container used
for shipping by air. The facility or component may land with the
aircraft and be unloaded from the aircraft for use or the facility
or component may be used while on board the aircraft. In certain
embodiments, the facility or component is dropped from the air to
the site where it is to be used. In certain embodiments, the
facility or component includes parachutes or other landing device
for a safe landing of the facility. The facility may also include a
floatation device for a water landing. In certain embodiments, the
facility or a component thereof includes a means for absorbing the
impact of the landing. In certain embodiments, the facility or
components is later moved by land, air, or water to a new site. In
other embodiments, the facility or components are not moved and may
be abandoned temporarily or permanently. Various other components
of a facility may be transported by land or water as well as air.
The components may be assembled into an operational facility at an
airport, landing strip, drop site, or any other land or water
site.
[0086] In certain embodiments, the facilities or any of its
components are capable of being transported by any combination of
air, land, and/or water transport. In certain embodiments, the
facility or its components are transported by all three. In other
embodiments, the facility or its components are transported by land
and water. In certain embodiment, the facility or its components
are transported by land and air. In other embodiments, the facility
or its components are transported by air and water. In these cases,
the vehicle transporting the facility or any of its components
preferably meets the requirements (e.g., length, width, height, and
weight) of the mode of transportation being used. Given that the
ethanol, hydrocarbons, natural gas, or gasoline being produced are
flammable, any applicable safety laws, rules, or regulations are
preferably followed regarding the transport and production of a
flammable liquids or gases. In certain embodiments, equipment for
handling spills, fires, and explosions is incorporated into the
facility.
[0087] In certain embodiments, the facilities include at least one
portable component used in the production of energy (e.g., ethanol,
hydrocarbons, gasoline, natural gas, methane, biodiesel, and
hydrogen gas), electricity, plastics, polymers, nutrients (human
and animal), proteins, biomolecules, pharmaceuticals (human and
veterinary; e.g., drugs and medicines), fertilizer, or other
products from biomass. The assembled facility as well as any
components of the facility are considered to be within the scope of
the disclosure. A component-based facility allows for easy assembly
of the facility, interchangeability, scalability, and
pre-fabrication of the components. Breaking the facility into
various components also facilitates the mobility aspect of the
facility. In certain embodiments, the facility is divided into two,
three, four, five, six, seven, eight, nine, ten, or more
components. Each component may include one or more pieces of
equipment with the necessary wiring, piping, drains, control
systems, heating and cooling means, stands, coupling devices, and
outlets. In certain embodiments, the component includes walls,
roof, flooring, or other infrastructure for the component itself,
other components, or the entire facility. In certain embodiments,
the component includes a contained for easy transport of the
component. The container may be used in the production process
(e.g., as a mixing container or other vat). The sides, bottom, or
top of the container may be used as the walls, floor, or roof of
the shelter housing the facility or components thereof.
[0088] In certain embodiments, each step of the production process
is performed in a separate component. That is, all the equipment
for a step in the process is included in the component. The various
steps and equipment useful in the production of bioethanol from
biomass are described herein. In other embodiments, a step may
require equipment from one or more components. In other
embodiments, more than one step of the production process is
included in a component. One or more components of the facility are
assembled to produce an operable facility. The components are
typically assembled at a site prepared for the installation.
However, in certain embodiments, there is no preparation or
infrastructure at the site. Instead, the facility or components are
self-supporting. In certain embodiments, the components are
assembled using a crane, fork lift, truck, or other moving device,
which is optionally included in the system. In other embodiments,
the components are assembled using only human labor. Tools may be
used in the assembly of the facility. The site may include all the
necessary infrastructure to make the facility operational.
Infrastructure may include walls, roof, foundation, floor,
electricity, wiring, piping, sewer, water, and natural gas. In
certain embodiments, the infrastructure is not mobile and is
stationary. When the facility or any of its components are moved,
the infrastructure may be left behind to potentially be used again
the future. In certain embodiments, the infrastructure is used to
assemble a production facility every month, every season, every
year, or any time sufficient biomass is available at the site to
supply the facility.
[0089] Ethanol production facilities that are smaller in scale than
traditional ethanol production facilities. Typically, ethanol
production facilities produce greater than 10-20 million gallons of
ethanol per year with some facilities exceeding 50 million gallons
of ethanol per year. The facilities produce less than 5 million
gallons of ethanol or other energy source per year. In certain
embodiments, the facility produces less than 1 million gallons of
ethanol or other energy source per year. In certain embodiments,
the facility produces less than 0.5 million gallons of ethanol or
other energy source per year. In certain embodiments, the facility
produces less than 0.1 million gallons of ethanol or other energy
source per year. In certain embodiments, the facility produces less
than 0.01 million gallons of ethanol or other energy source per
year. In certain embodiments, the facility produces less than 0.001
million gallons of ethanol or other energy source per year. These
facilities may be mobile or include mobile components as described
herein. In certain embodiments, the facility is stationary. The
amount of energy produced by a facility is sufficient to meet the
demands of a factory, military base, small town, rural village,
county, farm, and island. The small size of the facility allows for
numerous facilities to be placed in a geographic region. For
example, a facility may be placed in any areas where there is
sufficient biomass (e.g., crops, waste) to supply the facility
with. Smaller-scale facilities closer to the biomass being
processed by the system reduce transportation costs, and in certain
cases, may allow ethanol to be produced economically where it could
not be produced economically by large-scale facilities.
[0090] The bioethanol production facilities can have all or some of
the equipment necessary for producing the desired product from
biomass. The biomass used by the systems include any type of
biomass. In certain embodiments, more conventional sources of
biomass such as corn, sugar beets, grains, sugar cane, or whey is
used as the starting material. In other embodiments, less
conventional sources of biomass are used including agricultural
waste, algae, waste, and human waste. In certain embodiments, the
systems do not use corn, sugar beets, or sugarcane. In certain
embodiments, the systems do use corn. In other embodiments, the
system uses sugar beets or sugarcane. In certain embodiments, the
system is designed to use a variety of different types of biomass
as starting material. In other embodiments, the system is designed
to use one type of biomass. In certain embodiments, various
components may be switched interchanged to allow for different
types of biomass as starting materials.
[0091] In certain embodiments, the systems include processes and
apparatuses for pre-processing the biomass. In certain embodiments,
the biomass is sorted. In other embodiments, the biomass is
cleaned. In other embodiments, the biomass is packaged. In certain
embodiments, the biomass is compacted or compressed. In other
embodiments, the biomass is liquefied. In other embodiments, the
biomass is dehydrated. The pre-processing of the biomass may take
place at the site of harvesting the biomass, before transportation
of the biomass, during the transportation, during storage of the
biomass, or at the site of the energy production. Any equipment and
methods used to pre-process biomass for energy production may be
used. In certain embodiments, the pre-processing means is
considered to be part of the system.
[0092] The process of producing energy (e.g., ethanol,
hydrocarbons, gasoline, natural gas, methane, biodiesel, and
hydrogen gas), electricity, plastics, polymers, nutrients (human
and animal), proteins, biomolecules, pharmaceuticals (human and
veterinary; e.g., drugs and medicines), fertilizer, or other
products from biomass can be broken down into several steps. The
first involves grinding the biomass into a fine powder, chopping
the biomass, shearing the biomass, or otherwise making the complex
carbohydrates or other biomolecules in the biomass available for
further processing. In certain embodiments, the resulting biomass
is then mixed with water and optionally microorganisms (e.g.,
bacteria), algae, enzymes, acid, base, or chemical reagent. The
mixture is then optionally heated in a cooker or other apparatus to
facilitate the break-down of complex sugars (e.g., cellulose,
starch) into fermentable, simpler sugars (e.g., glucose). This step
may also facilitate the breakdown of other biomolecules or cellular
structures such as lipids, protein, nucleic acids, steroids,
natural products, cell wall, cell membrane, and intracellular
membranes. The resulting mixture, commonly known as the mash, is
then fermented with the addition of a microorganism such as yeast.
In certain embodiments, other genetically engineered microorganisms
are used in the fermentation process. The microorganisms may be
particularly suitable for fermenting or converting the biomass used
in the process into the desired product. The
fermentation/conversion process is continued until most of the
sugars or other starting materials in the fermentation have been
converted to ethanol or other desired product. In certain
embodiments, co-products such as carbon dioxide, proteins,
polymers, nutrients, fertilizers, or biomolecules are produced
during the process. These may be collected, purified, packaged,
and/or sold. The ethanol or other desired product is then
optionally separated from the liquid, solid waste, and side
products. This is typically done by distillation; however, other
means of separating or purifying can also be used (e.g. column
chromatography, extraction, chromatography, and crystallization).
The distilled ethanol or other liquid energy source may still
contain water so the desired product is optionally dehydrated. In
certain embodiments, the desired product (e.g., ethanol) is
dehydrated by running it over a substance that absorbs the
remaining water such as molecular sieves. Once the desired product
(e.g., ethanol) is purified to the desired degree of purity and
water is removed, the desired product, particularly ethanol, is
optionally denatured making it unfit for human consumption. The
denaturation process is performed by missing the purified ethanol
with 1-5% of gasoline or other organic solvent (e.g., methanol,
acetone, isopropanol, and hexanes). Any waste can be discarded. In
certain embodiments, the resulting distillers grain is used as
livestock feed or as a fertilizer. Carbon dioxide also is produced
as a by-product in the fermentation process. The carbon dioxide may
be collected and sold. Other products such as polymers, protein,
lipids, or other biomolecules are side products may be collected,
packaged, and/or sold.
[0093] In certain embodiments, for example, when bioethanol is
being produced from biomass, the facility or a component thereof
includes a fermenter and distillation apparatus. In other
embodiments, the production facility or component thereof also
includes a cooker. The facility may also include a mill for
grinding the biomass into smaller particles. The facility may also
contain equipment such as columns for further purifying and
dehydrating the ethanol after distillation. In certain embodiments,
the facility also includes containers and mixing equipment for
denaturing the produced ethanol. In certain embodiments, the
various equipment is interconnected using piping to easily transfer
the product from one step into equipment for performing the next
step. As needed, the various equipment used in the process is
fitted with heating and cooling means.
[0094] The process begins with biomass. The biomass used by the
system may be any biomass suitable for producing ethanol or any
other desired product. In certain embodiments, the biomass is high
starch or high sugar agricultural crops such as corn, sugar cane,
sugar and beets. The facilities are particularly useful and
economical in converting crops to bioethanol because they can
arrive or be assembled at the site when the crops (or other
biomass) are ready for processing and then leave or be disassembled
when the crops (or other biomass) have been processed. In certain
embodiments, the biomass includes materials that contain cellulose,
hemicellulose, lignin, protein, starch, and/or sugar. In certain
embodiments, the biomass includes plant matter such as trees,
shrubs, grasses, weeds, agricultural crops, and agricultural waste.
In certain embodiments, the biomass includes aquatic biomass, for
example plankton, aquatic plants, and algae. Aquatic biomass is
particularly suitable for being processed by the production
facilities that are transported on water. In certain embodiments,
the biomass is municipal waste, waste paper, and yard waste. A
production facility may routinely travel to a particular area to
convert its waste to ethanol or another desired product, or the
facility may be assembled at a particular site. In other
embodiments, the biomass is human waste.
[0095] The initial phases of sizing, milling, chopping, cutting,
shearing, washing, liquefication, and/or saccharification of the
biomass are performed by the facility or components thereof in some
embodiments. In other embodiments, these steps or some of these
steps are not performed by the facility or components thereof.
[0096] In certain embodiments, the biomass is mechanically broken
down. For example, in certain embodiments, the sizing, milling,
chopping, cutting, shearing, washing, or other pre-processing of
the biomass for fermentation or conversion is not performed by the
facility or components thereof, and the resulting processed biomass
(also known as the meal) is the starting material used by the
facility or a component thereof. In certain embodiments, the
facility or a component thereof processes the biomass to allow for
microoganisms or chemical to act on the carbohydrates in the
biomass. This may include breaking down cell membranes, breaking
down cells walls, increasing the surface area, breaking down
macrostructures in the biomass.
[0097] In certain embodiments, the biomass or cellulose in the
biomass is texturized or opened up as described in U.S. Pat. Nos.
5,952,105; 5,973,035; 6,207,729; 6,258,876; 6,448,307; 7,074,918;
each of which is incorporated herein by reference; and published
U.S. patent applications 20050084671; 20050090577; 20050200050;
each of which is incorporated herein by reference. This process
opens up the fibers in the biomass for further processing by
chemicals and microoganisms added to the processed biomass in
subsequent steps. The process increases the surface area where
microorganisms or chemicals can work.
[0098] Referring to FIG. 2, a rotary knife cutter 20 includes a
hopper 22 that can be loaded with a shredded fiber source 10'
prepared by shredding fiber source 10. Shredded fiber source 10' is
sheared between stationary blades 24 and rotating blades 26 to
provide a first fibrous material 12. First fibrous material 12
passes through screen 16, and the resulting second fibrous material
4 is captured in bin 30. To aid in the collection of the second
fibrous material 4, bin 30 can have a pressure below nominal
atmospheric pressure, e.g., at least 10 percent below nominal
atmospheric pressure, e.g., at least 25 percent below nominal
atmospheric pressure, at least 50 percent below nominal atmospheric
pressure, or at least 75 percent below nominal atmospheric
pressure. In some embodiments, a vacuum source 50 is utilized to
maintain the bin below nominal atmospheric pressure.
[0099] In certain embodiments, the biomass is mixed with water and
optionally enzymes, microorganisms (e.g., bacteria, fungi, yeast),
algae, other organisms, chemical reagents, or a combination
thereof. This step breaks down the cellular structures, sugars, and
biomolecules of the biomass before its conversion into the desired
product. In certain embodiments, the biomass is mixed with a
microorganism that aids in the breakdown of the biomass. The
microorganism may be genetically engineered. In certain
embodiments, the biomass is mixed with an algae that aids in the
breakdown of the biomass. The resulting mixture may be heated,
cooled, and mixed. to effect the desired changes to the biomass. In
certain embodiments, the biomass is substantially liquefied
resulting in a mash before it is transferred to the facility or a
component thereof. In still other embodiments, the complex sugars
in the mash are broken down into simpler, fermentable sugars, and
the resulting mash is transferred to the facility or a component
thereof for processing.
[0100] Once the biomass or a processed form of the biomass (e.g.,
the meal, the mash, opened and fiber) enters the facility or
component thereof, it is further processed to form ethanol or any
other desired product. In certain embodiments, the facility or a
component pre-processes, liquefies, and converts the complex sugars
in the mash to simpler sugars. In other embodiments the facility or
a component thereof liquefies and converts the complex sugars to
simpler sugars for distillation. In still other embodiments, the
complex sugar in the mash are converted to simpler sugars in the
facility or a component thereof. This conversion process is
effected by enzymes such as amylase or cellulase, acid (e.g.,
sulfuric acid), microorganisms, and/or heat. The conversion process
breaks down complex sugars such as cellulose and starch to simpler
5- or 6-carbon sugars such as glucose.
[0101] Once the mash with the broken down sugars is obtained either
through processing inside or outside the facility, the
fermentation/conversion process is begun. In certain embodiments,
the mash is fermented to produce ethanol. The fermentation process
is typically begun by bringing the mash to a particular
temperature, for example, between 30 and 45.degree. C. In certain
embodiments, the fermentation takes place at approximately
30.degree. C. In certain embodiments, the pH of the mash is
adjusted to approximately pH 6-8, preferably approximately pH
7-7.5. In certain embodiments, the fermentation is carried out in
an oxygen-depleted atmosphere. A fermenting microorganism is then
added to the mash. In certain embodiments, the fermenting
microorganism is yeast. In other embodiments, the fermenting
microorganism is Saccharomyces cerevisiae. In certain embodiments,
the fermenting organism is Schizosaccharomyces pombe. In other
embodiments, the microorganism is Zymomonas mobilis. In other
embodiments, the microorganism is Escherichia coli. In certain
embodiments, the microorganism is a genetically engineered
organism. Examples of genetically engineered fermenting organisms
useful in the production of bioethanol are described in U.S. Pat.
Nos. 6,699,696; 6,306,639; 5,162,516; 5,028,539; 5,000,000;
4,400,470; each of which is incorporated herein by reference. In
certain embodiments, the fermentation mixture is kept at a constant
temperature and pH during the fermentation process. The
fermentation typically last from 24 hours to 500 hours. In certain
embodiments, the fermentation lasts from 50-200 hours. In certain
other embodiments, the fermentation last from 100-200 hours. As
would be appreciated by one of skill in this art, the biomass,
microorganism, temperature, and other conditions used in the
fermentation will determine the length of time needed to convert
the biomass to ethanol.
[0102] In other embodiments, the processed biomass or mash is
converted into another energy source besides ethanol (e.g.,
gasoline, hydrocarbons, hydrogen gas, natural gas, biodiesel, and
electricity) or another desired product or co-product. This
conversion is affected by microorganisms. In certain embodiments,
the microorganisms are genetically engineered. In certain
particular embodiments, the microorganisms are genetically
engineered to produce the desired product. For example, in certain
embodiments, the microorganisms are designed to produce natural gas
or hydrogen gas from biomass. In other embodiments, the
microorganisms are designed to produce gasoline or hydrocarbons
from biomass.
[0103] In other embodiments, the processed biomass or mash is
converted into other desired products such as plastics, polymers,
and nutrients. This conversion is affected by microorganisms. In
certain embodiments, the microorganisms are genetically engineered.
In certain particular embodiments, the microorganisms are
genetically engineered to produce the desired polymer. In certain
embodiments, the microorganisms are designed to produce
nutrients.
[0104] In certain embodiments, the desired product is removed as it
is produced. In other embodiments, the desired product is purified
from the fermentation/conversion after the fermentation/conversion
is stopped. In the production of bioethanol, after the fermentation
step is complete, the fermented mash (also known as beer) contains
anywhere from 5% to 20% ethanol. In some embodiments, the ethanol
is removed as it is produced. The ethanol is purified from the
water, and solids by distillation. The distillation process
involves vaporizing the ethanol and then recondensing it into
liquid form again. The purity of the ethanol obtained from the
distillation can be increased by repeatedly distilling the
resulting ethanol until the desired purity is achieved. The ethanol
may be further purified by removing any remaining water using a
dehydration step. In certain embodiments, the ethanol is passed
over a material which absorbs water such as molecular sieves. In
certain embodiments, the ethanol is distilled or azeotroped to
remove most of the water from the ethanol. Similarly, if a
different desired product is produced than ethanol, it can
similarly be purified from the converted biomass. Preferably, as
much of the desired product is produced before the conversion
process is stopped. In certain embodiments, the desired product is
drawn off as it is produced.
[0105] Analogously, the facilities may produce 100% ethanol or
ethanol of any desired state of purity. For example, the facility
with its distillation apparatus may produce less than 100% pure
ethanol. In certain embodiments, the ethanol is at least 80%, at
least 90%, at least 95%, at least 98%, or at least 99% pure. The
ethanol, if desired, can then be further purified and/or dehydrated
outside the mobile facility. In certain embodiments, the facility
produces pure ethanol that is subsequently denatured. An organic
solvent such as methanol, isopropanol, hexanes, and gasoline. is
added to the purified ethanol to produced denatured ethanol, which
is unfit for human consumption. Exemplary denaturants include
methanol, camphor, aldehydes, amyl alcohol, gasoline, isopropanol,
terpineol, benzene, castor oil, acetone, nicotine, acids, kerosene,
and diethyl phthalate. In certain embodiments, 1-10% of organic
solvent is added to the ethanol. In other embodiments, 1-5% of
organic solvent is added. In certain embodiments, 2-5% of gasoline
is added to the ethanol to denture it.
[0106] Any of the knowledge in the art of producing of ethanol from
biomass may be used in the system for producing ethanol. Various
aspects of the process of producing ethanol from biomass are
described in U.S. Pat. Nos. 7,070,967; 7,037,704; 7,037,378;
7,033,781; 7,026,152; 7,022,894; 6,933,404; 6,927,048; 6,908,995;
6,861,248; 6,849,434; 6,846,657; 6,803,218; 6,755,975; 6,737,257;
6,716,631; 6,703,227; 6,699,696; 6,663,780; 6,660,506; 6,648,930;
6,605,376; 6,596,908; 6,592,921; 6,582,944; 6,555,350; 6,528,311;
6,509,180; 6,468,567; 6,420,146; 6,387,554; 6,379,964; 6,372,269;
6,355,456; 6,352,859; 6,335,198; 6,335,177; 6,333,181; 6,326,204;
6,306,639; 6,287,862; 6,280,986; 6,267,309; 6,251,674; 6,224,915;
6,136,577; 6,130,076; 6,107,093; 6,090,595; 6,054,611; 6,045,660;
6,001,568; 5,981,807; 5,975,439; 5,958,698; 5,932,456; 5,916,787;
5,916,780; 5,892,107; 5,882,905; 5,869,301; 5,840,971; 5,821,093;
5,789,210; 5,779,164; 5,756,862; 5,735,916; 5,705,369; 5,677,154;
5,616,478; 5,609,723; 5,578,472; 5,571,703; 5,559,031; 5,554,520;
5,545,543; 5,504,259; 5,503,996; 5,488,185; 5,487,989; 5,482,846;
5,474,924; 5,470,433; 5,424,417; 5,424,202; 5,407,817; 5,397,436;
5,372,939; 5,345,477; 5,258,293; 5,231,017; 5,223,567; 5,186,722;
5,182,199; 5,135,861; 5,134,944; 5,106,634; 5,100,791; 5,086,144;
5,081,285; 5,071,675; 5,063,156; 5,061,497; 5,047,332; 5,028,539;
5,013,436; 5,000,000; 4,985,355; 4,952,504; 4,952,503; 4,933,198;
4,886,751; 4,885,241; 4,859,758; 4,840,903; 4,840,902; 4,830,964;
4,816,407; 4,816,399; 4,812,410; 4,808,527; 4,808,526; 4,790,238;
4,778,688; 4,769,324; 4,746,615; 4,746,610; 4,731,329; 4,661,643;
4,650,689; 4,647,534; 4,628,031; 4,612,286; 4,604,352; 4,567,145;
4,560,659; 4,556,744; 4,541,897; 4,523,928; 4,522,920; 4,517,298;
4,510,242; 4,507,505; 4,490,469; 4,490,468; 4,480,090; 4,454,358;
4,451,597; 4,447,534; 4,443,637; 4,443,544; 4,443,543; 4,442,210;
4,421,939; 4,413,058; 4,409,405; 4,405,815; 4,403,034; 4,400,551;
4,400,470; 4,400,469; 4,395,488; 4,393,136; 4,386,009; 4,372,822;
4,358,536; 4,357,480; 4,356,262; 4,355,192; 4,355,108; 4,346,113;
4,335,207; 4,333,852; 4,328,375; 4,326,036; 4,321,141; 4,317,884;
4,302,357; 4,301,312; 4,301,253; 4,287,303; 4,273,621; 4,262,154;
4,255,300; 4,253,987; 4,233,466; 4,220,803; 4,168,391; 4,164,445;
4,139,509; 4,134,926; 4,094,742; each of which is incorporated
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OTHER EMBODIMENTS
[0107] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. Accordingly, other embodiments are within
the scope of the following claims.
* * * * *