JP2017527267A - バイオマスの処理 - Google Patents
バイオマスの処理 Download PDFInfo
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- JP2017527267A JP2017527267A JP2017501700A JP2017501700A JP2017527267A JP 2017527267 A JP2017527267 A JP 2017527267A JP 2017501700 A JP2017501700 A JP 2017501700A JP 2017501700 A JP2017501700 A JP 2017501700A JP 2017527267 A JP2017527267 A JP 2017527267A
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- JP
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- Prior art keywords
- less
- feedstock
- biomass
- membrane filter
- bioprocessed
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
Description
本願は、2014年7月21日に出願された米国仮特許出願第62/026,742号および2014年7月22日に出願された米国仮特許出願第62/027,489号の利益を主張するものであり、上記出願の内容は参照により本明細書に組み込まれる。
本明細書に記載される設備、方法およびシステムを用いれば、例えばバイオマス(例えば、植物バイオマス、動物バイオマス、紙および都市廃棄物バイオマス)から供給され得るセルロース系およびリグノセルロース系供給原料物質を有用な生成物および中間体、糖類をはじめとする生成物(例えば、発酵生成物)に変化させることができる。膜ろ過を用いてスラリーをろ過する設備、方法およびシステムが本明細書に開示される。例えば、バイオマス工程ストリームの質を高める精密ろ過および限外ろ過などのクロスフロー膜ろ過技術が記載される。
糖化
糖化には、ASME鉢形ヘッド(頂部および底部)を備えた直径32インチ(約81cm)、高さ64インチ(約160cm)の円柱型タンクを用いた。タンクはほかにも、幅16インチ(約41cm)の水中翼攪拌ブレードを備えていた。タンクを取り囲むハーフパイプジャケットの中に熱水を流すことによって加熱した。
糖化し篩にかけた原料約400mLを1LのNew Brunswick BioFlow 115バイオリアクターの中に傾瀉した。原料に通気し30℃に加熱した後、接種した。攪拌を50rpmに設定した。pHの測定値は5.2であり、この値は発酵に許容されるため、調整しなかった。通気を止め、バイオリアクターの内容物にTHERMOSACC(登録商標)乾燥酵母(Lallemand社)を5mg接種した。約24時間発酵させた。
規模を拡大したこと(300gal(約1100l))以外は上記のものと同様にトウモロコシ穂軸を糖化し発酵させた。さらに、(酵素による加水分解の前に)100〜160℃で加熱することによりトウモロコシ穂軸を前処理した。下の表1の固形物のパーセントおよび粒子径のデータは3つの工程ストリーム試料、すなわち、A.発酵後、B.デカンタ遠心分離機を用いた後およびC.デカンタ遠心分離した原料を取り出して約90℃に加熱し、ディスク遠心分離機を用いて原料をさらに処理した後の試料から得られたものである。第二の高速デカンタ遠心分離機によって、ディスク遠心分離機とほぼ同じ粒径分布が得られ、総懸濁固形物(TSS)が減少すると予想される。
限外ろ過を用いて、上記のようにデカンタ遠心分離機で得られた工程ストリームを精製し得る。デカンタ遠心分離機で得られた固形物を約0.21%含有する工程ストリーム50ガロン(約190l)をパイロットランのタンジェンシャル限外ろ過システムで処理し得る。限外ろ過膜では、A37管状膜モジュール(PCI membranes社、ハミルトン、オハイオ州)を用いて1回通過させる。第一の膜フィルターは、カットオフが200kDa(約0.1μm)の管状膜であり得る。原料をこの膜に約5〜6GPM(約19〜約23l/分)の供給速度で通して処理する。約24時間後、この第一のモジュールによるろ過が終了し、約90gal(約340l)の通過物と10gal(約38l)の濃縮物が得られる。カットオフが20kDaのA37管状膜モジュールを用いて、90gal(約340l)の通過物を5〜6GPM(約19〜約23l/分)の速度で1回通過させて処理する。この処理によって約80gal(約300l)の通過生成物と10gal(約38l)の濃縮物が得られる。
リグノセルロース系またはセルロース系原料などの供給原料を照射により処理してその構造を変化させ、その抵抗性を減少させ得る。このような処理によって、例えば、供給原料の平均分子量が小さくなり、供給原料の結晶構造が変化し、かつ/または供給原料の表面積および/または多孔度が増大し得る。照射は、例えば、電子ビーム、イオンビーム、100nm〜28nmの紫外(UV)光、ガンマ線またはX線の照射によるものであり得る。照射処理および処理システムについては、米国特許第8,142,620号および米国特許仮出願第12/417,731号(その開示全体が参照により本明細書に組み込まれる)で論じられている。
本発明は、放射線不透過性材料を用いて建造されたボールトおよび/またはバンカー内の原料(例えば、リグノセルロース系またはセルロース系供給原料)を処理することを含み得る。一実施形態では、多くの材料を通過することが可能な高エネルギー(短波長)のX線から成分を遮蔽するため、放射線不透過性材料を選択する。放射線を遮蔽する囲いを設計するうえで重要な因子の1つは使用する材料の減衰長であり、これによって特定の材料、材料の混合物または層構造に必要な厚さが決まる。減衰長とは、放射線が入射放射線の約1/e(e=オイラー数)倍まで減少する透過距離のことである。十分な厚さがあれば、実質的にあらゆる材料が放射線不透過性になるが、Z値(原子番号)の大きい元素の組成割合(例えば、密度)が高い材料の方が放射線の減衰長が短く、したがって、このような材料を使用すれば、より薄くて軽い遮蔽をもたらすことができる。放射線遮蔽に使用される高Z値材料の例として、タンタルおよび鉛がある。放射線遮蔽に重要なまた別のパラメータには半減距離があり、これはガンマ線強度が50%減少する特定の材料の厚さのことである。一例を挙げれば、エネルギーが0.1MeVのX線照射では、半減厚さはコンクリートが約15.1mm、鉛が約2.7mmとなり、X線エネルギーが1MeVであれば、コンクリートの半減厚さは約44.45mm、鉛の半減厚さは約7.9mmとなる。放射線不透過性材料は、反対側まで通過する放射線を減少させることができる限り、厚い材料であっても薄い材料であってもよい。したがって、例えば重量を軽くするため、または大きさに制約があるため、特定の囲いの壁厚を薄くすることが望まれるのであれば、選択する材料は、半減長が囲いの所望の壁厚以下になるのに十分なZ値および/または減衰長を有するべきである。
供給原料(例えば、リグノセルロース系またはセルロース系原料)の処理に用いる照射線の種類によって、使用する線源の種類ならびに照射装置およびその関連設備が決まる。本明細書に記載される照射線で原料を処理する方法、システムおよび設備は、本明細書に記載される入手源のほかにも、他の任意の有用な入手源用いるものであり得る。
電子加速器の抽出システムは2つの窓箔を含み得る。2つの箔窓抽出システム内の冷却ガスは、パージガスまたは混合物、例えば空気または純ガスであり得る。一実施形態では、ガスは、窒素、アルゴン、ヘリウムおよび/または二酸化炭素などの不活性ガスである。電子ビームに対するエネルギー損失が最小限に抑えられることから、液体よりも気体を使用する方が好ましい。このほか、窓または窓と窓の間隙に衝突させる前に純ガスを事前に混合するか、配管内で混合した混合物を使用し得る。冷却ガスは、例えば、熱交換システム(例えば、冷却機)および/または凝縮ガス(例えば、液体窒素、液体ヘリウム)からのボイルオフを用いることによって冷却され得る。窓箔については、2013年10月10日に出願された国際出願PCT/US2013/64332号(開示全体が参照により本明細書に組み込まれる)に記載されている。
電子ビームの電子が物質と非弾性衝突で相互作用すると、バイオマス内でいくつかの過程が起こり得る。例えば、原料のイオン化、原料中のポリマーの鎖切断、原料中のポリマーの架橋、原料の酸化、X線の発生(「制動放射」)および分子の振動励起(例えば、フォノン発生)がある。特定の機序に束縛されるものではないが、抵抗性の減少は、これらの非弾性衝突効果のうちのいくつか、例えばイオン化、ポリマーの鎖切断、酸化およびフォノン発生に起因し得る。これらの効果のいくつか(例えば、特にX線発生)は、遮蔽および遮断壁の設計、例えば照射工程をコンクリート(またはその他の放射線不透過性材料)製のボールトで囲うことが必要である。照射のまた別の効果である振動励起は、試料の加熱と同じものである。照射による試料の加熱は抵抗性の減少を促進し得るが、過剰な加熱は、以下で説明するように原料を破壊し得る。
いくつかの実施形態では、(例えば、リグノセルロース系またはセルロース系供給原料の照射に電子ビーム照射を用いる)システムおよび方法は、ビームストップ(例えば、シャッター)を含む。例えば、ビームストップを用いて、電子ビーム装置の出力を下げずに原料の照射を迅速に遮断または減少させることができる。あるいは、電子ビームの出力を上げながらビームストップを用いることができ、例えば、ビームストップによって、所望のレベルのビーム電流に達するまで電子ビームを遮断することができる。ビームストップは、第一の箔窓と第二の箔窓との間に設置し得る。例えば、ビームストップを移動可能なように、すなわちビーム経路の内外に移動できるように取り付け得る。例えば照射の線量を制御するのに、ビームの部分的覆いを用いることもできる。ビームストップは、床、バイオマスのコンベア、壁、照射装置(例えば、スキャンホーンの位置)または任意の構造支持体に取り付け得る。好ましくは、ビームがビームストップによって効率的に制御され得るように、ビームストップをスキャンホーンと関連付けて固定する。ビームストップは、それがビームの内外に移動して稼働できるようにするヒンジ、レール、ホイール、スロットをはじめとする手段を組み込み得る。ビームストップは、電子の少なくとも5%、例えば、電子の少なくとも10%、20%、30%、40%、50%、60%、70%、少なくとも80%、85%、90%、91%、92%、93%、94%、95%、96%、97%、98%、99%または場合によっては約100%を遮断する任意の材料でできたものであり得る。
このほか、本明細書に開示される(例えば、リグノセルロースまたはセルロース系供給原料の照射に電離放射線を用いる)実施形態は、照射処理を用いる場合、ビームダンプを含み得る。ビームダンプの目的は、荷電粒子ビームを安全に吸収することである。ビームストップと同じく、ビームダンプを用いて荷電粒子ビームを遮断することができる。しかし、ビームダンプはビームストップよりもはるかに堅牢なものであり、全出力の電子ビームを長時間にわたって遮断することを目的とするものである。ビームダンプは、加速器の出力を上げながらビームを遮断するのに使用されることが多い。
リグノセルロース系原料(例えば、糖化する供給原料)としては、特に限定されないが、木材、削片板、林業廃棄物(例えば、おがくず、アスペン材、木片)、草木(例えば、スイッチグラス、ススキ、コードグラス、クサヨシ)、穀物残渣(例えば、米穀、オートムギ殻、コムギもみ殻、オオムギ殻)、農業廃棄物(例えば、貯蔵牧草、カノーラわら、コムギわら、オオムギわら、オートムギわら、米わら、黄麻、大麻、亜麻、竹、サイザル麻、マニラ麻、トウモロコシ穂軸、トウモロコシ茎葉、ダイズ茎葉、トウモロコシ繊維、アルファルファ、乾草、ヤシ毛)、糖加工残渣(例えば、バガス、テンサイパルプ、リュウゼツランバガス)、藻、海藻、堆厩肥、下水およびそのいずれかの組合せが挙げられる。
本明細書に記載される方法、設備およびシステムを用いて、その他の原料(例えば、天然原料または合成原料)、例えばポリマーを処理および/または作製することができる。例えば、ポリエチレン(例えば、直鎖状低密度エチレンおよび高密度ポリエチレン)、ポリスチレン、スルホン化ポリスチレン、ポリ(塩化ビニル)、ポリエステル(例えば、ナイロン、DACRON(商標)、KODEL(商標))、ポリアルキレンエステル、ポリビニルエステル、ポリアミド(例えば、KEVLAR(商標))、ポリエチレンテレフタラート、酢酸セルロース、アセタール、ポリアクリロニトリル、ポリカルボナート(例えば、LEXAN(商標))、アクリル樹脂[例えば、ポリ(メチルメタクリラート)、ポリ(メチルメタクリラート)、ポリアクリロニトリル]、ポリウレタン、ポリプロピレン、ポリブタジエン、ポリイソブチレン、ポリアクリロニトリル、ポリクロロプレン(例えば、ネオプレン)、ポリ(シス−1,4−イソプレン)[例えば、天然ゴム]、ポリ(トランス−1,4−イソプレン)[例えば、グッタペルカ]、フェノールホルムアルデヒド、メラミンホルムアルデヒド、エポキシド、ポリエステル、ポリアミン、ポリカルボン酸、ポリ乳酸、ポリビニルアルコール、ポリ酸無水物、ポリフルオロカーボン(例えば、TEFLON(商標))、シリコン(例えば、シリコーンゴム)、ポリシラン、ポリエーテル(例えば、ポリエチレンオキシド、ポリプロピレンオキシド)、ろう、油およびその混合物がある。このほか、プラスチック、ゴム、エラストマー、繊維、ろう、ゲル、油、接着剤、熱可塑性プラスチック、熱硬化プラスチック、生分解性ポリマー、このようなポリマーで作製した樹脂、その他のポリマー、その他の原料およびその組合せが挙げられる。ポリマーは、カチオン重合、アニオン重合、ラジカル重合、メタセシス重合、開環重合、グラフト重合、付加重合を含めた任意の有用な方法によって作製され得る。いくつかの場合には、本明細書に開示される処理を例えばラジカルグラフト重合および架橋に用い得る。このほか、ポリマーと例えばガラス、金属、バイオマス(例えば、繊維、粒子)、セラミックとの複合材料を処理および/または作製することができる。
バイオマスは、例えば含水率が約35%未満(例えば、約20%未満、約15%未満、約10%未満、約5%未満、約4%未満、約3%未満、約2%未満または約1%未満)の乾燥形態であり得る。またバイオマスは湿潤状態で、例えば、固体が少なくとも約10重量%(例えば、少なくとも約20重量%、少なくとも約30重量%、少なくとも約40重量%、少なくとも約50重量%、少なくとも約60重量%、少なくとも約70重量%)の湿潤固形物、スラリーまたは懸濁液として供給され得る。
必要に応じて、照射に代えて、またはこれに加えて、1つまたは複数の超音波処理、熱分解、酸化または水蒸気爆砕工程を用いて炭水化物含有原料の抵抗性を減少またはさらに減少させ得る。例えば、これらの工程を照射前、照射時および照射後に適用し得る。これらの工程については、Medoffに対する米国特許第7,932,065号(開示全体が参照により本明細書に組み込まれる)に詳細に記載されている。
本明細書に記載される工程を用いて、バイオマス原料をエネルギー、燃料、食料および材料などの1つまたは複数の生成物に変換し得る。例えば、有機酸、有機酸の塩、無水物、有機酸のエステルおよび燃料など、例えば内燃機関の燃料または燃料電池の供給原料などの中間体および生成物がある。本明細書には、入手は容易であるが処理が困難な場合が多いセルロース系および/またはリグノセルロース系原料、例えば、都市廃棄物ストリームおよび古紙ストリーム、例えば新聞紙、クラフト紙、段ボール紙またはその混合物を含むストリームなどを供給原料として使用することができるシステムおよび工程が記載される。
記載される方法によってリグノセルロース処理から得られる使用済みバイオマス(例えば、使用済みリグノセルロース系原料)はリグニン含有量が多く、コジェネレーションプラントで燃焼させてエネルギーを生産するのに有用であることに加えて、それ以外にも価値ある生成物としての用途を有し得ると予想される。例えば、リグニンをプラスチックとして捕捉し使用する、または合成的に他のプラスチックに質を高めることができる。いくつかの場合には、リグノスルホン酸に変換してもよく、これを結合剤、分散剤、乳化剤または捕捉剤として使用し得る。
供給原料を容易に処理が可能な形態に変換するために、糖化剤、例えば酵素または酸、糖化と呼ばれる過程によって、供給原料中のグルカン含有またはキシラン含有セルロースを糖などの低分子量炭水化物に加水分解し得る。次いで、低分子量炭水化物を例えば、単細胞タンパク質工場、酵素製造プラントまたは燃料プラント、例えばエタノール製造施設などの既存の製造プラントで使用し得る。
適切なセルロース分解酵素としては、バチルス(Bacillus)属、コプリナス(Coprinus)属、ミセリオフトラ(Myceliophthora)属、セファロスポリウム(Cephalosporium)属、シタリジウム(Scytalidium)属、ペニシリウム(Penicillium)属、アスペルギルス(Aspergillus)属、シュードモナス(Pseudomonas)属、ヒューミコラ(Humicola)属、フサリウム(Fusarium)属、チエラビア(Thielavia)属、アクレモニウム(Acremonium)属、クリソスポリウム(Chrysosporium)属およびトリコデルマ(Trichoderma)属の種由来のセルラーゼ、特にアスペルギルス(Aspergillus)種(例えば、欧州特許第0458162号を参照されたい)、ヒューミコラ・インソレンス(Humicola insolens)(シタリジウム・サーモフィラム(Scytalidium thermophilum)として再分類された;例えば、米国特許第4,435,307号を参照されたい)、ネナガヒトヨタケ(Coprinus cinereus)、フサリウム・オキシスポラム(Fusarium oxysporum)、ミセリオフトラ・サーモフィラ(Myceliophthora thermophila)、トンビマイタケ(Meripilus giganteus)、チエラビア・テレストリス(Thielavia terrestris)、アクレモニウム(Acremonium)種(特に限定されないが、A.ペルシシナム(A.persicinum)、A.アクレモニウム(A.acremonium)、A.ブラキペニウム(A.brachypenium)、A.ジクロモスポラム(A.dichromosporum)、A.オブクラバタム(A.obclavatum)、A.ピンケルトニエ(A.pinkertoniae)、A.ロセオグリセウム(A.roseogriseum)、A.インコロラタム(A.incoloratum)およびA.フラタム(A.furatum)を含む)の種から選択される菌株によって産生されるセルロース分解酵素が挙げられる。好ましい菌株としては、ヒューミコラ・インソレンス(Humicola insolens)DSM1800、フサリウム・オキシスポラム(Fusarium oxysporum)DSM2672、ミセリオフトラ・サーモフィラ(Myceliophthora thermophila)CBS117.65、セファロスポリウム(Cephalosporium)種RYM−202、アクレモニウム(Acremonium)種CBS 478.94、アクレモニウム(Acremonium)種CBS 265.95、アクレモニウムペルシシナム(Acremonium persicinum)CBS169.65、アクレモニウム・アクレモニウム(Acremonium acremonium)AHU9519、セファロスポリウム(Cephalosporium)種CBS535.71、アクレモニウム・ブラキペニウム(Acremonium brachypenium)CBS866.73、アクレモニウム・ジクロモスポラム(Acremonium dichromosporum)CBS683.73、アクレモニウム・オブクラバタム(Acremonium obclavatum)CBS311.74、アクレモニウム・ピンケルトニエ(Acremonium pinkertoniae)CBS157.70、アクレモニウム・ロセオグリセウム(Acremonium roseogriseum)CBS134.56、アクレモニウム・インコロラタム(Acremonium incoloratum)CBS146.62およびアクレモニウム・フラタム(Acremonium furatum)CBS299.70Hが挙げられる。このほか、クリソスポリウム(Chrysosporium)、好ましくはクリソスポリウム・ラックノウェンス(Chrysosporium lucknowense)の菌株からセルロース分解酵素を得てもよい。使用できるほかの菌株としては、特に限定されないが、トリコデルマ(Trichoderma)(特にT.viride、T.リーセイ(T.reesei)およびT.コニンギィ(T.koningii)、好アルカリ性バチルス(Bacillus)(例えば、米国特許第3,844,890号および欧州特許第0458162号を参照されたい)およびストレプトミセス(Streptomyces)(例えば、欧州特許第0458162号を参照されたい)が挙げられる。
本明細書に記載の工程で、例えば糖化後、糖(例えば、グルコースおよびキシロース)を単離し得る。例えば、沈殿、結晶化、クロマトグラフィー(例えば、擬似移動層式クロマトグラフィー、高圧クロマトグラフィー)、遠心分離、抽出、当該技術分野で公知の他の任意の単離方法およびその組合せによって糖を単離し得る。
本明細書に記載の工程には水素化が含まれ得る。例えば、グルコースおよびキシロースをそれぞれソルビトールおよびキシリトールに水素化し得る。水素化は、高圧下(例えば、10〜12000psi(約69kPa〜約8.3×104kPa)、約100〜10,000psi(約690〜69,000kPa)、触媒(例えば、Pt/ガンマ−Al203、Ru/C、ラネーニッケルをはじめとする当業者に公知の触媒)をH2と組み合わせて用いることによって実施し得る。本明細書に記載の工程で得られた生成物の他の種類の化学変換、例えば、有機糖由来の生成物(例えば、フルフラールおよびフルフラール由来の生成物)の生成を用いてもよい。糖由来生成物の化学変換については、2013年7月3日に出願された米国特許出願第13/934,704(開示全体が参照により本明細書に組み込まれる)に記載されている。
酵母およびザイモモナス(Zymomonas)菌を例えば、糖(1つまたは複数)からアルコール(1つまたは複数)への発酵または変換に用い得る。その他の微生物については以下で論じる。発酵の最適は約pH4〜7である。例えば、酵母の最適pHはpH約4〜5であり、ザイモモナス(Zymomonas)の最適pHはpH約5〜6である。典型的な発酵時間は、20℃〜40℃(例えば、26℃〜40℃)の範囲の温度で約24〜168時間(例えば、24〜96時間)であるが、好熱性微生物はこれよりも高い温度を好む。
発酵に用いる微生物(1つまたは複数)は、天然の微生物および/または組換え微生物であり得る。例えば、微生物は細菌(特に限定されないが、例えばセルロース分解細菌が挙げられる)、真菌(特に限定されないが、例えば酵母が挙げられる)、植物、原生生物、例えば、原生動物もしくは真菌様原生生物(特に限定されないが、例えば粘菌が挙げられる)または藻であり得る。生物体に適合性がある場合、生物体の混合物を用いてもよい。
発酵後、得られた液体を、例えば「ビアカラム」を用いて蒸留し、エタノールをはじめとするアルコールと水および固形残留物の大部分とを分離し得る。蒸留は(例えば、溶液中の糖などの生成物の分解を抑えるため)真空下で実施され得る。ビアカラムから出る蒸気は、例えば、少なくとも35重量%(例えば、少なくとも40重量%、少なくとも50重量%または少なくとも90重量%)のエタノールであり得、精留カラムへ送られ得る。気相分子篩を用いて、ほぼ共沸性の(例えば、少なくとも約92.5%)のエタノールと精留カラムの水の混合物が純粋な(少なくとも約99.5%または場合によっては約100%の)エタノールに精製され得る。ビアカラムの残液は三重効用蒸発缶の第一効用缶へ送られ得る。精留カラムの還流冷却器により、この効用缶に熱が加えられ得る。第一効用缶の後、遠心分離を用いて固体を分離し、回転乾燥機で乾燥させ得る。遠心分離の排出液の一部(25%)は発酵に再利用し、残りは蒸発缶の第二および第三効用缶へ送られ得る。蒸発缶の濃縮物のほとんどは、きわめて清浄な濃縮物として工程に戻すことができ、ごく一部のものは、低沸点化合物の蓄積の防ぐため分離して廃水処理に回す。
本明細書に記載される方法およびシステムを用いる他の実施形態では、炭化水素含有原料を処理し得る。本明細書に記載される任意の工程を用いて、本明細書に記載される任意の炭化水素含有原料を処理することができる。本明細書で使用される「炭化水素含有原料」は、オイルサンド、オイルシェール、タールサンド、炭粉、石炭スラリー、ビチューメン、様々な種類の石炭をはじめとする炭化水素成分と固形分の両方を含む天然原料および合成原料を包含するものとする。固形分には、岩、砂、粘土、石、沈泥、掘削スラリーをはじめとする有機および/または無機固形分が含まれ得る。この用語はほかにも、掘削の廃棄物および副生成物、精製の廃棄物および副生成物をはじめとする炭化水素成分含有廃棄物などの廃棄物、例えばアスファルトシングルおよびアスファルトカバー、アスファルト舗装などを包含し得る。
様々な運搬システムを用いてバイオマス原料を例えば、ボールトおよびボールト内の電子ビーム下に運搬し得る。例示的な運搬装置には、ベルトコンベア、空気コンベア、スクリューコンベア、カート、列車、レール上の列車またはカート、エレベータ、フロントローダ、バックホー、クレーン、様々なスクレーパおよびショベル、トラックがあり、投入装置を用い得る。例えば、本明細書に記載される様々な工程に振動コンベアを用い得る。振動コンベアについては、2013年10月10日に出願された国際出願PCT/US2013/64289号(開示全体が参照により本明細書に組み込まれる)に記載されている。
本明細書に記載される任意の原料、工程または処理済み原料を用いて、生成物および/または中間体、例えば複合材料、充填剤、結合剤、プラスチック添加剤、吸着剤および放出制御剤などを作製し得る。この方法は、例えば原料への加圧および加熱による高密度化処理を含み得る。例えば、繊維性原料と樹脂またはポリマーとを組み合わせることによって複合材料を作製し得る。例えば、照射架橋樹脂、例えば熱可塑性樹脂と繊維性原料とを組み合わせて、繊維性原料/架橋性樹脂の組合せが得られる。このような材料は、例えば、建築材料、保護シート、容器をはじめとする構造材料(例えば、成形物および/または押出物)として有用であり得る。吸収剤は例えば、ペレット、チップ、繊維および/またはシートの形態であり得る。吸着剤は例えば、ペット床敷、包装材料として、または公害防止システムに使用され得る。放出制御マトリックスは例えば、ペレット、チップ、繊維またはシートの形態であり得る。放出制御マトリックスは例えば、薬物、殺生物剤、香料を放出させるのに使用され得る。例えば、複合材料、吸収剤および放出制御剤およびその使用については、2006年3月23日に出願された米国特許出願PCT/US2006/010648号および2011年11月22日に出願された米国特許第8,074,910号(開示全体が参照により本明細書に組み込まれる)に記載されている。
例えば本明細書に記載される工程システムおよび/または設備によって作製される、本明細書に記載されるいずれかの生成物および/または中間体を香味料、香料、着色料および/またはその混合物と組み合わせ得る。例えば、(任意選択で、香味料、香料および/または着色料とともに)糖、有機酸、燃料、ポリオール、例えば糖アルコールなど、バイオマス、繊維および複合材料のいずれか1つまたは複数のものを組み合せて(例えば、製剤化して、混合して、または反応させて)または用いて、他の生成物を作製し得る。例えば、1つまたは複数のこのような生成物を用いて、石鹸、界面活性剤、キャンディ、飲料(例えば、コーラ、ワイン、ビール、ジンまたはウォッカなどの酒類、スポーツ飲料、コーヒー、茶)、医薬品、接着剤、シート(例えば、織布、不織布、繊維、ティッシュ)および/または複合材料(例えば、板)を作製し得る。例えば、1つまたは複数のこのような生成物をハーブ、花、花弁、スパイス、ビタミン、ポプリまたはキャンドルと組み合わせ得る。例えば、製剤化、混合または反応済みの組合せは、グレープフルーツ、オレンジ、リンゴ、ラズベリー、バナナ、レタス、セロリ、シナモン、チョコレート、バニラ、ペパーミント、ミント、オニオン、ガーリック、コショウ、サフラン、ショウキョウ、ミルク、ワイン、ビール、茶、牛赤身肉、魚、ハマグリ、オリーブ油、ココナッツ脂、豚脂、バター脂、ビーフブイヨン、莢果、ジャガイモ、マーマレード、ハム、コーヒーおよびチーズの香味/香を有し得る。
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Claims (33)
- 第一の膜フィルターを用いて、バイオ処理済み供給原料から前記バイオ処理済み供給原料由来の第一の分子量前後を上回る分子量を有する原料を保持することによって、前記バイオ処理済み供給原料から第一の通過物を生成することと、
第二の膜フィルターを用いて、前記第一の通過物から前記第一の通過物由来の第二の分子量前後を上回る分子量を有する原料を保持することによって、前記第一の通過物から第二の通過物を生成することと、
を含む、精製方法。 - 前記バイオ処理済み供給原料が、バイオマス原料の糖化によって生成される、請求項1に記載の方法。
- 糖化が、前記バイオマス原料と酵素または生物とを接触させることによって実施される、請求項2に記載の方法。
- 前記バイオマス原料が、セルロース系原料またはリグノセルロース系原料である、請求項2または3に記載の方法。
- 前記バイオ処理済み供給原料が、約1%未満、約0.5%未満、約0.2%未満または約0.1%未満の固形物を含むスラリーの形態である、請求項1〜4のいずれか1項に記載の方法。
- 前記固形物が、約10μm未満、約5μm未満または約1μm未満の粒子径中央値を有する、請求項5に記載の方法。
- 前記第一の膜フィルターを用いる前に、前記バイオ処理済み供給原料をろ過して固形物を除去する、請求項5または6に記載の方法。
- 前記バイオ処理済み供給原料が、ろ過される前に少なくとも約1%の固形物、少なくとも約3%の固形物または少なくとも約9%の固形物を含む、請求項7に記載の方法。
- 前記バイオ処理済み供給原料が、デカンタ遠心分離、ディスク遠心分離、積層ろ過、プレートろ過、精密ろ過、カラムろ過、振動型膜分離装置およびその組合せ(例えば、連続して用いる2種類の遠心分離)から選択される方法によってろ過される、請求項7または8に記載の方法。
- 前記バイオ処理済み供給原料が発酵生成物である、請求項1〜9のいずれか1項に記載の方法。
- 前記バイオ処理済み供給原料が、少なくとも1つの糖を含む蒸留残渣である、請求項1〜10のいずれか1項に記載の方法。
- 前記バイオ処理済み供給原料が、キシロース、約0.1%〜約50%のキシロース、約0.5%〜約30%のキシロース、約1%〜約20%のキシロースまたは約1%〜約10%のキシロースを含む、請求項1〜11のいずれか1項に記載の方法。
- 前記バイオ処理済み供給原料が、前記第一の膜フィルターによってろ過される前に、真空下で少なくとも1つの揮発性化合物が除去されている、請求項1〜12のいずれか1項に記載の方法。
- 前記揮発性化合物が、エステル、酪酸エステルまたは乳酸エステルである、請求項13に記載の方法。
- 前記揮発性化合物がアルコール(例えば、エタノール、ブタノール)である、請求項13に記載の方法。
- 前記バイオ処理済み供給原料中のアルコールの濃度が、約5%未満、約1%未満、約0.5%未満または約0.1%未満である、請求項14に記載の方法。
- 前記第一の分子量が前記第二の分子量よりも大きい、請求項1〜16のいずれか1項に記載の方法。
- 前記第一の分子量が、少なくとも約100kDa、少なくとも約150kDaまたは少なくとも約200kDaである、請求項1〜17のいずれかに記載の方法。
- 前記第一の膜フィルターが、前記バイオ処理済み供給原料から約0.05μm超、約0.06μm超、約0.07μm超、約0.08μm超、約0.09μm超または約0.1μm超の粒子を保持する、請求項1〜18のいずれか1項に記載の方法。
- 前記第二の分子量が、少なくとも約2kDa、約2kDa〜約100kDa、約2kDa〜約50kDaまたは約4kDa〜約20kDaである、請求項1〜19のいずれか1項に記載の方法。
- 前記第一の通過物が、液化バイオマスよりも濁度が低い、または前記第一の通過物が、約5ネフェロ分析濁度単位未満もしくは約1ネフェロ分析濁度単位未満の濁度を有する、または前記第二の通過物が、少なくとも約5NTU、少なくとも約10NTUもしくは少なくとも約50NTUの濁度を有する、請求項1〜20のいずれか1項に記載の方法。
- 前記第二の通過物が、前記第一の通過物よりも色が薄い、または前記第二の通過物が、白金−コバルトASTM試験法D1209による約200単位未満、約100単位未満、約50単位未満、約40単位未満、約30単位未満、約20単位未満、約10単位未満、約5単位未満もしくは約1単位未満の色を有する、請求項1〜21のいずれか1項に記載の方法。
- 前記第一の膜フィルターと前記第二の膜フィルターが、クロスフローフィルターとして構成されている、請求項1〜22のいずれか1項に記載の方法。
- 前記第一の膜フィルターおよび/または前記第二の膜フィルターが、らせん巻きフィルター、チューブフィルターまたは中空糸フィルターである、請求項23に記載の方法。
- 前記第一の膜フィルターおよび/または前記第二の膜フィルターが、直径約1/4〜約1インチ(約0.64〜約2.5cm)または約1/2インチ(約1.3cm)のチューブフィルターとして構成されている、請求項23に記載の方法。
- 前記第一の膜フィルターおよび/または前記第二の膜フィルターの入口圧が約90〜約500PSIG(約620〜約3400kPa)または約100〜約250PSIG(約690〜1700kPa)であり、前記第一の膜フィルターおよび/または前記第二の膜フィルターの出口圧が約20〜約430PSIG(約140〜約3000kPa)または約20〜約150PSIG(約140〜約1030kPa)である、請求項23に記載の方法。
- 前記バイオ処理済み供給原料が、チューブの中を流速約1〜約20GPM(約3.8〜約76l/分)、約2〜約10GPM(約7.6〜38l/分)または約4〜約6GPM(約15〜約23l/分)で流れる、請求項25または26に記載の方法。
- 前記第一の膜フィルターおよび/または前記第二の膜フィルターが、1モジュール当たり2束以上、7束以上、19束以上または37束以上のチューブフィルターを含むモジュールとして構成されている、請求項25〜27のいずれか1項に記載の方法。
- 2つ以上、3つ以上、4つ以上、5つ以上、6つ以上または7つ以上のモジュールを用いて前記液化バイオマス原料および/または前記第一の通過物を処理する、請求項28に記載の方法。
- 前記バイオ処理済み供給原料および前記第一の通過物が、前記第一の膜フィルターおよび前記第二の膜フィルターでろ過されたとき、その温度が約30〜約70℃、約40〜約65℃、約40〜約50℃である、請求項1〜29のいずれか1項に記載の方法。
- (例えば、三重効用蒸発器などの蒸発器を用いて、ナノろ過を用いて、逆浸透を用いて)前記第一の通過物を濃縮することをさらに含む、請求項1〜30のいずれか1項に記載の方法。
- (例えば、三重効用蒸発器などの蒸発器を用いて、ナノろ過を用いて、逆浸透を用いて)前記第二の通過物を濃縮することをさらに含む、請求項1〜31のいずれか1項に記載の方法。
- 蒸発器、電気透析、逆電気透析、擬似移動ビーズクロマトグラフィー(simulated moving bead chromatography)およびその組合せからなる群より選択されるシステムを用いて前記第二の通過物を処理する、請求項1〜32のいずれか1項に記載の方法。
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