CA2597135A1 - Continuous counter-current organosolv processing of lignocellulosic feedstocks - Google Patents
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Abstract
A modular process for organosolv fractionation of lignocellulosic feedstocks into component parts and further processing of said component parts into at least fuel-grade ethanol and four classes of lignin derivatives. The modular process comprises a first processing module configured for physico-chemically digesting lignocellulosic feedstocks with an organic solvent thereby producing a cellulosic solids fraction and a liquid fraction, a second processing module configured for producing at least a fuel-grade ethanol and a first class of novel lignin derivatives from the cellulosic solids fraction, a third processing module configured for separating a second class and a third class of lignin derivatives from the liquid fraction and further processing the liquid fraction to produce a distillate and a stillage, a fourth processing module configured for separating a fourth class of lignin derivatives from the stillage and further processing the stillage to produce a sugar syrup.
Claims (48)
1. A modular process for organosolv fractionation of a lignocellulosic feedstock into component parts and further processing of said component parts; the modular process comprising:
a first processing module provided with a first series of steps for receiving, physically screening, and physico-chemically digesting a lignocellulosic feedstock with an aqueous organic solvent separately provided thereto thereby extracting component parts therefrom, and separating said component parts into a cellulosic solids fraction and a first liquid fraction;
a second processing module provided with a second series of steps for producing at least a fuel-grade ethanol and a plurality of a first class of lignin derivatives from said cellulosic solids fraction;
a third processing module provided with a third series of steps comprising at least a first step for separating the first liquid fraction into a second solids fraction comprising a plurality of a second class of lignin derivatives and a first filtrate, a second step for separating the first filtrate into a third solids fraction comprising a plurality of a third class of lignin derivatives and a second filtrate, and a third step for separating furfurals from said filtrate, a fourth step for recovering a portion of the aqueous organic solvent from the filtrate by distillation thereby producing a first stillage; and a fourth processing module provided with a fourth series of steps for separating the first stillage into at least an acetic acid-containing liquid fraction, a plurality of a fourth class of lignin derivatives, a lipophylic extractives fraction, a monosaccharide sugar syrup, and a solid waste material.
a first processing module provided with a first series of steps for receiving, physically screening, and physico-chemically digesting a lignocellulosic feedstock with an aqueous organic solvent separately provided thereto thereby extracting component parts therefrom, and separating said component parts into a cellulosic solids fraction and a first liquid fraction;
a second processing module provided with a second series of steps for producing at least a fuel-grade ethanol and a plurality of a first class of lignin derivatives from said cellulosic solids fraction;
a third processing module provided with a third series of steps comprising at least a first step for separating the first liquid fraction into a second solids fraction comprising a plurality of a second class of lignin derivatives and a first filtrate, a second step for separating the first filtrate into a third solids fraction comprising a plurality of a third class of lignin derivatives and a second filtrate, and a third step for separating furfurals from said filtrate, a fourth step for recovering a portion of the aqueous organic solvent from the filtrate by distillation thereby producing a first stillage; and a fourth processing module provided with a fourth series of steps for separating the first stillage into at least an acetic acid-containing liquid fraction, a plurality of a fourth class of lignin derivatives, a lipophylic extractives fraction, a monosaccharide sugar syrup, and a solid waste material.
2. A modular process according to claim 1, additionally provided with a fifth processing module comprising an anaerobic digestion module configured for processing the solid waste material separated in the fourth processing module, into at least a collectable biogas and an liquid effluent.
3. A modular process according to claim 1, wherein the first processing module is configured to continuously receive, physically process, and physico-chemically digest a lignocellulosic feedstock thereby continuously producing the cellulosic solids fraction and the first liquid fraction.
4. A modular process according to claim 1, wherein the first processing module is configured to receive, physically process, and physico-chemically digest a batch of lignocellulosic feedstock thereby producing the cellulosic solids fraction and the first liquid fraction.
5. A modular process according to claim 1, wherein the aqueous organic solvent comprises at least one solvent selected from the group containing methanol, ethanol, butanol, propanol, and aromatic alcohols.
6. A modular process according to claim 1, wherein the aqueous organic solvent comprises at least ethanol.
7. A modular process according to claim 3, wherein the first series of steps comprises steps for physically separating non-lignocellulosic materials from the lignocellulosic feedstock, delivering said lignocellulosic feedstock into a first end of a heatable and pressurizable digestion vessel, said vessel heated and pressurized, conveying said lignocellulosic feedstock to about a second end of the digestion vessel, commingling said lignocellulosic feedstock with said aqueous organic solvent and producing therefrom the cellulosic solids fraction and the first liquid fraction, discharging the solids fraction from about the second end of the digestion vessel, and discharging the first liquid fraction from about the first end of the digestion vessel.
8. A modular process according to claim 7, wherein the lignocellulosic feedstock is commingled with the aqueous organic solvent by counterflowing said aqueous organic solvent from about the second end to about the first end the digestion vessel.
9. A modular process according to claim 7, wherein the lignocellulosic feedstock is commingled with the aqueous organic solvent by re-circulating said aqueous organic solvent therewithin and about the digestion vessel.
10. A modular process according to claim 7, wherein the first series of steps additionally comprises steps for controllably saturating the lignocellulosic feedstock with a heated aqueous organic solvent for a selected period of time, and for controllably removing the heated aqueous organic solvent from the lignocellulosic feedstock prior to delivering said lignocellulosic feedstock into about the first end of the digestion vessel
11. A modular process according to claim 1, wherein the second series of steps comprises steps for controllably reducing the viscosity of the cellulosic solids fraction, controllably digesting the reduced-viscosity cellulosic solids fraction to produce a second liquid fraction comprising at least soluble sugars, controllably fermenting the second liquid fraction to produce a beer therefrom, distilling the beer to produce a fuel-grade ethanol and a second stillage therefrom, and separating a first class of lignin derivatives from said second stillage.
12. A modular process according to claim 11, herein the second series of steps comprises a step for adding an enzyme preparation configured for controllably digesting the reduced-viscosity cellulosic solids fraction, said enzyme preparation comprising at least one enzyme selected from the group consisting of cellulases, hemicellulases, .beta.-glucosidases, .beta.-xylosidases xylanases, .alpha.-amylases, .beta.-amylases, and pullulases.
13. A modular process according to claim 11, herein the second series of steps comprises a step for adding an inoculum preparation configured for controllably fermenting the second liquid fraction, the inoculum preparation comprising at least one microbial strain selected from a group containing yeast strains, fungal strains and bacterial strains.
14. A modular process according to claim 13, herein the inoculum preparation comprises at least one microbial strain selected from a group containing naturally occurring Saccharomyces spp. strains, genetically engineered Saccharomyces spp. strains, naturally occurring Pichia spp.
strains and genetically engineered Pichia spp. strains.
strains and genetically engineered Pichia spp. strains.
15. A modular process according to claim 13, wherein the inoculum preparation comprises at least one microbial strain selected from a group containing naturally occurring Aspergillus spp.
strains, genetically engineered Aspergillus spp. strains, naturally occurring Trichoderma spp.
strains and genetically engineered Trichoderma spp. strains.
strains, genetically engineered Aspergillus spp. strains, naturally occurring Trichoderma spp.
strains and genetically engineered Trichoderma spp. strains.
16. A modular process according to claim 11, herein the inoculum preparation comprises at least one microbial strain selected from a group containing naturally occurring Escherichia coli strains, genetically engineered Escherichia coli strains, naturally occurring Zymomonas spp.
strains, genetically engineered Zymomonas spp. strains, naturally occurring Clostridium spp. strains, genetically engineered Clostridium spp. strains, naturally occurring Corynebacterium spp. strains, and genetically engineered Corynebacterium spp. strains.
strains, genetically engineered Zymomonas spp. strains, naturally occurring Clostridium spp. strains, genetically engineered Clostridium spp. strains, naturally occurring Corynebacterium spp. strains, and genetically engineered Corynebacterium spp. strains.
17. A modular process according to claim 11, wherein said digestion step and said fermentation step are concurrently performed within a single vessel.
18. A modular process according to claim 11, wherein said de-lignified second stillage is used to controllably reduce the viscosity of the cellulosic solids fraction.
19. A modular process according to claim 1, wherein the third series of steps additionally comprises steps for recycling the recovered portion of the organic solvent into the first processing module.
20 A modular process according to claim 19, wherein the recovered portion of the organic solvent is controllably intermixed with a portion of the fuel-grade ethanol produced by the second processing module.
21. A modular process according to claim 2, wherein the anaerobic digestion module comprises a first step of biologically liquifying said solid waste material thereby producing a third liquid fraction, a second step of biologically acidifying the third liquid fraction thereby producing a liquid organic acid stream therefrom, a third step of biologically acetifying the liquid organic stream thereby producing at least acetic acid, and a fourth step of biologically producing at least a biogas and a liquid effluent from said acetic acid.
22. A modular process according to claim 21, wherein the first step is additionally provided with an inoculation step wherein an inoculum comprising at least one microbial strain selected from a group containing at least naturally occurring strains of Enterobacter sp. and genetically engineered strains of Enterobacter sp., is controllably commingled with said solid waste material.
23. A modular process according to claim 21, wherein the second step is additionally provided with an inoculation step wherein an inoculum comprising at least one microbial strain selected from a group containing at least strains of naturally occurring Bacillus sp., strains of genetically engineered Bacillus sp., strains of naturally occurring Lactobacillus sp., strains of genetically engineered Lactobacillus sp., strains of naturally occurring Streptococcus sp., and strains of genetically engineered Streptococcus sp., is controllably commingled with said third liquid fraction.
24. A modular process according to claim 21, wherein the third step is additionally provided with an inoculation step wherein an inoculum comprising at least one microbial strain selected from a group containing at least strains of naturally occurring Acetobacter sp., strains of genetically engineered Acetobacter sp., strains of naturally occurring Gluconobacter sp., strains of genetically engineered Gluconobacter sp., strains of naturally occurring Clostridium sp., and strains of genetically engineered Clostridium sp., is controllably commingled with said liquid organic acid stream.
25. A modular process according to claim 21, wherein the fourth step is additionally provided with an inoculation step wherein an inoculum comprising at least one microbial strain selected from a group containing at least strains of naturally occurring Methanobacteria sp., strains of genetically engineered Methanobacteria sp., strains of naturally occurring Methanococci sp., strains of genetically engineered Methanobacteria sp., strains of naturally occurring Methanopyri sp., and strains of genetically engineered Methanopyri sp., is controllably commingled with said at least acetic acid.
26. A modular process according to claim 21, wherein a portion of the liquid monosaccharide sugar syrup produced in the fourth processing module is controllably delivered to the second step of the anaerobic digestion module for acidification therein.
27. A modular process according to claim 1, additionally provided with a sixth processing module comprising a fermentation module configured for receiving, fermenting and distilling therein said monosaccharide sugar syrup, and for separating therefrom a distillate and a stillage.
28. A modular process according to claim 27, wherein said distillate comprises at least 1,3 propanediol.
29. A modular process according to claim 27, wherein said distillate comprises at least lactic acid.
30. A modular system for organosolv fractionation of lignocellulosic feedstock into component parts and further processing of said component parts; the modular process comprising:
a first processing module configured for receiving, physically processing, and physico-chemically digesting a lignocellulose feedstock therewith a separately supplied aqueous organic solvent thereby extracting component parts therefrom said feedstock, and separating said component parts into a cellulosic solids fraction and a first liquid fraction;
a second processing module configured for receiving therein said cellulosic solids fraction and for producing therefrom at least a fuel-grade ethanol, a first class of lignin derivatives, and a de-lignified stillage;
a third processing module configured for separating the first liquid fraction into a solids fraction comprising a second class of lignin derivatives, a third class of lignin derivatives and a filtrate, for separating furfurals from said filtrate, and for recovering a portion of the organic solvent from the filtrate by distillation thereby producing a first stillage;
and a fourth processing module configured for separating the first stillage into at least an acetic acid-containing liquid fraction, a fourth class of lignin derivatives, a monosaccharide sugar syrup, and a solid waste material.
a first processing module configured for receiving, physically processing, and physico-chemically digesting a lignocellulose feedstock therewith a separately supplied aqueous organic solvent thereby extracting component parts therefrom said feedstock, and separating said component parts into a cellulosic solids fraction and a first liquid fraction;
a second processing module configured for receiving therein said cellulosic solids fraction and for producing therefrom at least a fuel-grade ethanol, a first class of lignin derivatives, and a de-lignified stillage;
a third processing module configured for separating the first liquid fraction into a solids fraction comprising a second class of lignin derivatives, a third class of lignin derivatives and a filtrate, for separating furfurals from said filtrate, and for recovering a portion of the organic solvent from the filtrate by distillation thereby producing a first stillage;
and a fourth processing module configured for separating the first stillage into at least an acetic acid-containing liquid fraction, a fourth class of lignin derivatives, a monosaccharide sugar syrup, and a solid waste material.
31. A modular system according to claim 30, additionally provided with a fifth processing module configured for anaerobic digestion and processing of the solid waste material separated by the fourth processing module, into at least a collectable biogas and an liquid effluent.
32. A modular system according to claim 30, wherein the first processing module comprises a plurality of equipment selected and configured for controllable and manipulable communication and cooperation for:
receiving therein a lignocellulosic feedstock;
processing the lignocellulosic feedstock by physically separating non-lignocellulosic materials therefrom;
physico-chemically digesting the processed lignocellulosic feedstock by commingling said feedstock with a separately supplied aqueous organic solvent while controllably manipulating at least the temperature and pressure therein and thereabout, thereby producing the cellulosic solids fraction and the first liquid fraction; and separately and controllably discharging the cellulosic solids fraction and the first liquid fraction.
receiving therein a lignocellulosic feedstock;
processing the lignocellulosic feedstock by physically separating non-lignocellulosic materials therefrom;
physico-chemically digesting the processed lignocellulosic feedstock by commingling said feedstock with a separately supplied aqueous organic solvent while controllably manipulating at least the temperature and pressure therein and thereabout, thereby producing the cellulosic solids fraction and the first liquid fraction; and separately and controllably discharging the cellulosic solids fraction and the first liquid fraction.
33. A modular system according to claim 30, wherein the first processing module is configured to continuously receive, physically process, and physico-chemically digest a lignocellulosic feedstock thereby continuously producing the cellulosic solids fraction and the first liquid fraction.
34. A modular process according to claim 30, wherein the first processing module is configured to receive, physically process, and physico-chemically digest a batch of lignocellulosic feedstock thereby producing the cellulosic solids fraction and the first liquid fraction.
35. A modular system according to claim 30, wherein the first processing module is provided with a temperature-controllable and pressure-controllable digestion vessel configured to:
receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;
receive therein an organic solvent at about the second end, and to flow said aqueous organic solvent therethrough to about the first end;
discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and discharge the first liquid fraction through an outlet provided therefor approximate the first end.
receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;
receive therein an organic solvent at about the second end, and to flow said aqueous organic solvent therethrough to about the first end;
discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and discharge the first liquid fraction through an outlet provided therefor approximate the first end.
36. A modular system according to claim 35, wherein the temperature-controllable and pressure-controllable digestion vessel is configured to:
receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;
receive therein an aqueous organic solvent at about the first end, and to circulate said aqueous organic solvent therethrough and thereabout;
discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and discharge the first liquid fraction through an outlet provided therefor approximate the second end.
receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;
receive therein an aqueous organic solvent at about the first end, and to circulate said aqueous organic solvent therethrough and thereabout;
discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and discharge the first liquid fraction through an outlet provided therefor approximate the second end.
37. A modular system according to claim 35, wherein the temperature-controllable and pressure-controllable digestion vessel is configured to:
receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;
receive therein an aqueous organic solvent interposed the first end and second end, and to circulate said aqueous organic solvent therethrough and thereabout;
discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and discharge the first liquid fraction through an outlet provided therefor approximate the first end.
receive therein the processed lignocellulosic feed stock at about a first end and to convey said feedstock therethrough to about a second end;
receive therein an aqueous organic solvent interposed the first end and second end, and to circulate said aqueous organic solvent therethrough and thereabout;
discharge the cellulosic solids fraction through an outlet provided therefor approximate the second end; and discharge the first liquid fraction through an outlet provided therefor approximate the first end.
38. A modular system according to claim 30, wherein the first processing module is additionally provided with equipment configured to sequentially saturate and de-saturate the processed lignocellulosic feedstock prior to physico-chemically digesting said processed lignocellulosic feedstock.
39. A modular system according to claim 30, wherein the second processing module comprises a plurality of equipment selected and configured for controllable and manipulable communication and cooperation for:
receiving therein the cellulosic solids fraction discharged from the first processing module;
reducing the viscosity of the cellulosic solids fraction;
enzymatic digestion of the reduced-viscosity cellulosic fraction thereby producing a second liquid fraction;
fermentation of the second liquid fraction thereby producing a beer therefrom;
distillation of the beer thereby producing a fuel-grade ethanol and a second stillage therefrom; and separating a first class of lignin derivatives from said second stillage.
receiving therein the cellulosic solids fraction discharged from the first processing module;
reducing the viscosity of the cellulosic solids fraction;
enzymatic digestion of the reduced-viscosity cellulosic fraction thereby producing a second liquid fraction;
fermentation of the second liquid fraction thereby producing a beer therefrom;
distillation of the beer thereby producing a fuel-grade ethanol and a second stillage therefrom; and separating a first class of lignin derivatives from said second stillage.
40. A modular system according to claim 30, wherein the de-lignified second stillage is recyclable for reducing the viscosity of the cellulosic solids fraction.
41. A modular system according to claim 30, wherein the second processing module is provided with a vessel for containing therein concurrent enzymatic digestion of the reduced-viscosity cellulosic solids fraction and fermentation of the second liquid fraction produced therefrom.
42 A modular system according to claim 30, wherein the anaerobic digestion module is provided with a plurality of equipment configured for:
receiving and biologically hydrolyzing therein the solid waste material separated by the fourth processing module thereby producing a third liquid fraction;
receiving and biologically acidifying therein the third liquid fraction thereby producing a biologically acidified liquid fraction;
receiving and biologically acetifying therein the biologically acidified liquid fraction thereby producing at least acetic acid; and receiving the at least acetic acid and biologically producing at least a biogas and a liquid effluent therefrom.
receiving and biologically hydrolyzing therein the solid waste material separated by the fourth processing module thereby producing a third liquid fraction;
receiving and biologically acidifying therein the third liquid fraction thereby producing a biologically acidified liquid fraction;
receiving and biologically acetifying therein the biologically acidified liquid fraction thereby producing at least acetic acid; and receiving the at least acetic acid and biologically producing at least a biogas and a liquid effluent therefrom.
43. A modular system according to claim 42, wherein the anaerobic digestion module is additionally configured for controllably receiving and commingling a portion of said monosaccharide sugar syrup separated in the fourth processing module with the a third liquid fraction.
44. A modular system according to claim 30, additionally provided with a sixth processing module configured for receiving, fermenting and distilling therein said monosaccharide sugar syrup, and for separating therefrom a distillate and a stillage.
45. A modular system according to claim 44, wherein said distillate comprises at least 1,3 propanediol.
46. A modular system according to claim 44, wherein said distillate comprises at least lactic acid.
47. A first class of lignin derivatives, said first class of lignin derivatives produced by a process comprising:
a first step comprising hydrolizing a cellulosic solids material thereby producing a liquid stream containing at least soluble monosaccharides;
a second step comprising fermentation of said liquid stream containing at least soluble monosaccharides thereby producing a fermentation beer;
a third step comprising distillation of said beer to produce an ethanol and a stillage therefrom; and a fourth step of precipitating and separating lignin derivatives from said stillage.
a first step comprising hydrolizing a cellulosic solids material thereby producing a liquid stream containing at least soluble monosaccharides;
a second step comprising fermentation of said liquid stream containing at least soluble monosaccharides thereby producing a fermentation beer;
a third step comprising distillation of said beer to produce an ethanol and a stillage therefrom; and a fourth step of precipitating and separating lignin derivatives from said stillage.
48. A second class of lignin derivatives, said second class of lignin derivatives produced by a process comprising:
a first step comprising fractionating a lignocellulosic feedstock into a cellulosics solids fraction and a pressurized liquids fraction, and separating said fractions;
a second step comprising depressurizing and cooling the liquids fraction thereby precipitating a plurality of lignin derivatives from said liquids fraction;
and a third step comprising separating said precipitated plurality of lignin derivatives from said liquids fraction.
a first step comprising fractionating a lignocellulosic feedstock into a cellulosics solids fraction and a pressurized liquids fraction, and separating said fractions;
a second step comprising depressurizing and cooling the liquids fraction thereby precipitating a plurality of lignin derivatives from said liquids fraction;
and a third step comprising separating said precipitated plurality of lignin derivatives from said liquids fraction.
Applications Claiming Priority (10)
Application Number | Priority Date | Filing Date | Title |
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US91460907P | 2007-04-27 | 2007-04-27 | |
US60/914,609 | 2007-04-27 | ||
US94119707P | 2007-05-31 | 2007-05-31 | |
US94122007P | 2007-05-31 | 2007-05-31 | |
US60/941,197 | 2007-05-31 | ||
US60/941,220 | 2007-05-31 | ||
US94796207P | 2007-07-04 | 2007-07-04 | |
US60/947,962 | 2007-07-04 | ||
US11/839,378 | 2007-08-15 | ||
US11/839,378 US20080299628A1 (en) | 2007-05-31 | 2007-08-15 | Continuous counter-current organosolv processing of lignocellulosic feedstocks |
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CA2597135A1 true CA2597135A1 (en) | 2008-09-07 |
CA2597135C CA2597135C (en) | 2011-07-26 |
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CA2597135A Expired - Fee Related CA2597135C (en) | 2007-04-27 | 2007-08-24 | Continuous counter-current organosolv processing of lignocellulosic feedstocks |
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Cited By (8)
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