CA2855192A1

CA2855192A1 - A method for producing biobased chemicals from plant biomass

Info

Publication number: CA2855192A1
Application number: CA2855192A
Authority: CA
Inventors: John Peterson; Jian Wu; Christopher Yost
Original assignee: Vertichem Corp
Current assignee: Vertichem Corp
Priority date: 2011-11-09
Filing date: 2012-11-01
Publication date: 2013-06-20
Also published as: EP2776536A1; WO2013089928A1

Abstract

A method for utilizing biomass components, namely cellulose, hemicellose, and lignin, and converting them to value-added biobased chemical products is described herein. The present method provides treatments to obtain a plurality of component streams from biomass for producing derivative products while minimizing waste products.

Description

A METHOD FOR PRODUCING BIOBASED CHEMICALS FROM PLANT BIOMASS
This application claims priority to U.S. Serial No. 13/292,222 entitled A
METHOD FOR
PRODUCING BIOBASED CHEMICALS FROM PLANT BIOMASS (filed November 9, 2011), U.S. Serial No. 13/292,437 entitled A METHOD FOR PRODUCING BIOBASED
CHEMICALS FROM WOODY BIOMASS (filed November 9, 2011), U.S. Serial No.
13/292,531 entitled A METHOD FOR PRODUCING BIOBASED CHEMICALS FROM
AGRICULTURAL BIOMASS (filed November 9, 2011), and U.S, Serial No, 13/292,632 entitled A METHOD FOR PRODUCING BIOBASED CHEMICALS FROM CULTIVATED
PLANT BIOMASS (filed November 9, 2011). All of the forgoing patent applications are incorporated herein by reference.
I. Background [0001] Currently, the world faces depletion of fossil fuels while demands for these fuels are ever increasing. Petrochemicals provide an energy source and a component of the majority of raw materials used in many industries. In fact, approximately 95% of all chemicals manufactured today are derived from petroleum. However, this heavy reliance upon fossil fuels is creating harm to the environment. The burning of these fossil fuels has led to the pollution of air, water and land, as well as global warming and climate changes. Through the use of fossil fuels, the environment has been harmed, perhaps irreparably, in an effort to meet the nearly insatiable demand for energy and manufactured products. Fossil fuels are a finite natural resource, with the depletion of readily available oil reserves across the globe; the supply chain has shifted to more complex and environmentally risky production technologies.
A reduction in the use and conservation of fossil fuels is clearly needed. Some alternatives to fossil fuels, like solar power, wind power, geothermal power, hydropower, and nuclear power, are used to a degree. However, a more efficient use of renewable resources is always being sought.

[0002] As a stable and independent alternative to fossil fuels, biomass has emerged as a potentially inexhaustible resource for the production of energy, transportation fuels, and chemicals. The advantage in turning to domestic, renewable biomass for such purposes would SUBSTITUTE SHEET (RULE 26) be magnified during periods of an oil crisis, a price surge, or political unrest within oil producing regions of the world. Herein biomass consists essentially of plant biomass, including agricultural biomass, woody biomass, and cultivated plant biomass. Biomass can be freshly harvested, stored, recovered, or recycled. Biomass can be employed as a sustainable source of energy and is a valuable alternative to fossil fuels in the production of chemicals. More specifically, the biorefining of biomass into derivative products typically produced from petroleum could help to lessen the dependence on foreign crude oil. Biomass can become a key resource for chemical production in much of the world. Moreover, biomass, unlike petroleum, is renewable. Biomass can provide sustainable substitutes for petrochemically derived feedstocks used in existing markets.
II. Summary [0003] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key factors or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0004] Accordingly, described herein is a method for biorefining. It may include the steps of providing biomass and treating the biomass to provide a plurality of component streams.
The method may further include producing derivative products from the plurality of component streams.

[0005] In one implementation, the method for biorefining is provided herein, comprising the steps of: providing biomass; processing the biomass to provide a plurality of component streams; and producing derivative products from the plurality of component streams.

[0006] In another implementation, the biomass comprises plant biomass.

[0007] In still another implementation, plant biomass comprises woody biomass, agricultural biomass, and cultivated plant biomass.

SUBSTITUTE SHEET (RULE 26) [0008] In yet another implementation, woody biomass comprises at least one softwood biomass of softwood trees, softwood shrubs, and softwood bushes.

[0009] In still yet another implementation, woody biomass comprises at least one hardwood biomass of hardwood trees, hardwood shrubs, and hardwood bushes.

[0010] In one implementation, woody biomass comprises at least one hybrid biomass of hybrid trees, hybrid shrubs, and hybrid bushes.

[0011] In another implementation, woody biomass comprises at least one forest biomass of forest trees, forest shrubs, and forest bushes.

[0012] In still another implementation, woody biomass comprises at least one biomass of recycled wood, recovered wood, recycled wood products, and recovered wood products.

[0013] In yet another implementation, agricultural biomass comprises at least one agricultural biomass of agricultural plants, annual agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, and genetically modified annual agricultural plants.

[0014] In still yet another implementation, agricultural biomass comprises at least one perennial agricultural biomass of perennial agricultural plants, native perennial agricultural plants, hybrid perennial agricultural plants, and genetically modified perennial agricultural plants.

[0015] In one implementation, agricultural biomass comprises at least one biennial agricultural biomass of biennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants.

[0016] In another implementation, agricultural biomass comprises of at least one agricultural residue of agricultural plants, annual agricultural plants, perennial agricultural plants, biennial agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, SUBSTITUTE SHEET (RULE 26) genetically modified annual agricultural plants, native perennial agricultural plants, hybrid perennial agricultural plants, genetically modified perennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants.

[0017] In still another implementation, cultivated plant biomass comprises at least one biomass of cultivated plants, cultivated trees, cultivated shrubs, and cultivated bushes.

[0018] In yet another implementation, cultivated plant biomass comprises at least one cultivated plant of aquatic plants, medicinal plants, fiber plants, ornamental plants, and grassy plants.

[0019] In still yet another implementation, cultivated plant biomass comprises at least one annual cultivated plant of annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, and genetically modified annual cultivated plants.

[0020] In one implementation, cultivated plant biomass comprises at least one perennial cultivated plant of perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, and genetically modified perennial cultivated plants.

[0021] In another implementation, cultivated plant biomass comprises at least one biennial cultivated plant of biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants.

[0022] In still another implementation, cultivated plant biomass comprises cultivated plant residues of at least one of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial SUBSTITUTE SHEET (RULE 26) cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants.

[0023] In yet another implementation, the plurality of component streams comprises lignin, cellulose, and hemicellulose.

[0024] In still yet another implementation, the step of processing the biomass to provide a plurality of component streams comprises mechanical processing and component separation processing.

[0025] In one implementation, the mechanical processing comprises at least one mechanical process of chopping, chipping, cutting, shredding, debarking, milling, and grinding.

[0026] In another implementation, the biomass is woody biomass and the processing of the woody biomass by the mechanical processing comprises at least one of mechanical process of debarking, chopping, chipping, milling, and grinding.

[0027] In still another implementation, the biomass is agricultural biomass or cultivated plant biomass and the processing of the plant biomass by the mechanical processing comprises at least one of chopping, cutting, shredding, milling, and grinding.

[0028] In yet another implementation, the step of component separation processing further comprises the step of providing cellulose.

[0029] In still yet another implementation, the component separation processing comprises at least one component of lignin and hemicellulose.

[0030] In one implementation, the step of processing the biomass to provide a plurality of component streams further comprises the step of completing a chemical processing during the processing of the biomass.
SUBSTITUTE SHEET (RULE 26) [0031] In another implementation, the chemical processing comprises at least one treatment of solvent treatment, acidic treatment, basic treatment, and enzymatic treatment.

[0032] In still another implementation, the method described further comprises removing extractables from the chemical processing.

[0033] In yet another implementation, the step of removing extractables from the chemical processing further comprises the step of at least one process of extracting metals from ore, lubricating, cleaning, disinfecting, deodorizing, scenting, and producing biofuels.

[0034] In still yet another implementation, the method further comprises the steps of recovering chemicals from the chemical processing and recycling the chemicals from the chemical processing.

[0035] In one implementation, the method further comprises the step of using a residual chemical removal in the step of processing the biomass.

[0036] In another implementation, the step of using residual chemical removal produces hemicellulose and lignin.

[0037] In still another implementation, the step of using residual chemical removal further comprises the steps of adjusting a pH and producing hemicellulose and lignin.

[0038] In yet another implementation, the method further comprises the steps of recovering at least one chemical from the residual chemical removal and recycling the at least one chemical from the residual chemical removal.

[0039] In still yet another implementation, the step of processing the biomass to provide a plurality of component streams further comprises the step of utilizing an additional treatment during the processing of the biomass.

SUBSTITUTE SHEET (RULE 26) [0040] In one implementation, the additional treatment comprises at least one treatment of heat treatment, pressure treatment, kraft pulping, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment.

[0041] In another implementation, the method further comprises the step of selectively utilizing at least two of the additional treatments during the processing of the biomass.

[0042] In still another implementation, the method further comprises the step of removing extractables from the additional treatment.

[0043] In yet another implementation, the method further comprises the steps of recovering at least one chemical from the additional treatment and recycling at least one chemical from the additional treatment.

[0044] In still yet another implementation, the method further comprises the step of selectively utilizing one of the component streams for producing the derivative products.

[0045] In one implementation, the method further comprises the step of selectively utilizing at least two of the component streams for producing the derivative products.

[0046] In another implementation, the plurality of component streams is a mixture of the component streams.

[0047] In still another implementation, at least one component stream of the plurality of component streams is an independent and separate component stream from the plurality of component streams.

[0048] In yet another implementation, the method includes the step of selectively producing one derivative product from the independent and separate component stream.

SUBSTITUTE SHEET (RULE 26) [0049] In still yet another implementation, the method further comprises the step of selectively producing at least two derivative products from the independent and separate component stream.

[0050] In one implementation, the method further comprises the step of producing at least one derivative product from a residue component stream.

[0051] In another implementation, derivative products comprise at least one product of commodity chemicals, fine chemicals, and specialty chemicals.

[0052] In still another implementation, producing derivative products comprises at least one process of chemical processing, biological processing, catalytic processing, and pyrolytic processing.

[0053] In yet another implementation, one of the component streams is lignin, wherein derivative products from lignin comprise at least one product of aromatic chemicals and fuels.

[0054] In still yet another implementation, derivative products from lignin comprise at least one product of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, and pyrolytic oils.

[0055] In one implementation, derivative products from lignin comprise at least one product of methyl and ethyl 4-hydroxybenzoate, methyl and ethyl vanillate, methyl and ethyl syringate, 4-hydroxybenzoic acid, (4-hydroxyphenyl)acetic acid, vanillic acid, homovanillic acid, syringic acid, homosyringic acid, 4-hydroxybenzaldehyde, vanillin, syringaldehyde, 4-hydroxybenzyl alcohol, 2-(4-hydroxyphenyl)ethanol, vanillyl alcohol, homovanillyl alcohol, syringyl alcohol, homosyringyl alcohol, 4-hydroxyacetophenone, acetoguaiacone, acetosyringone, 4-hydroxystyrene, 3-methoxy-4-hydroxystyrene, 3,5-dimethoxy-4-hydroxystyrene. (4-hydroxypheny1)-1-propene, (4-hydroxypheny1)-2-propene, eugenol, iso-eugenol, syringeugenol, iso-syringeugenol, ethyl phenol, ethyl guaiacol, ethyl syringol, propyl SUBSTITUTE SHEET (RULE 26) phenol, propyl guaiacol, propyl syringol, cresol, creosol, syringyl creosol, phenol, guaiacol, syringol, benzene, toluene, xylene, ethyl benzene, propyl benzene, biphenyl, and pyrolytic oils.

[0056] In another implementation, one of the components streams is cellulose, and the derivative products from cellulose comprise at least one product of aliphatic chemicals, heterocyclic chemicals, and fuels.

[0057] In still another implementation, derivative products from cellulose comprise at least one product of cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and ethanol.

[0058] In yet another implementation, derivative products from cellulose comprise at least one product of cellulose acetate, cellulose propionate, cellulose benzoate, methyl and ethyl adipate, methyl and ethyl levulinate, methyl and ethyl succinate, methyl and ethyl 2,5-furandicarboxylate, adipic acid, levulinic acid, succinic acid, 2,5-furandicarboxylic acid, 3,4-dehydro-y-valerolactone, y-valerolactone, 2-methyltetrahydrofuran, sorbitol, hexane-1,6-diol, pentane-1,4-diol, butane-1.4-diol, 2.5-di(hydroxymethyl)furan, 2,5-di(hydroxymethyl)tetrahydrofuran, glyercol, propylene glycol, and ethanol.

[0059] In still yet another implementation, method of claim 1, wherein one of the component streams is hemicellulose, and the derivative products from hemicellulose comprise at least one product of aliphatic chemicals, heterocyclic chemicals, and fuels.

[0060] In one implementation, derivative products from hemicellulose comprise at least one product of polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and butenes.

[0061] In another implementation, derivative products from hemicellulose comprise at least one product of furfural, ybutyrolactone, tetrahydrofuran, ribitol, arabitol, xylitol, glyercol, propylene glycol, and isoprene.

SUBSTITUTE SHEET (RULE 26) [0062] In still another implementation, the plurality of derivative products comprises at least one of product of achiral, racemic, and optically pure products.

[0063] In yet another implementation, the method further comprises the step of using at least one of the derivative products in the production of other chemicals, materials, and products.

[0064] In still yet another implementation, the biomass has a weight, and a waste product of the biomass is less than 25% of the biomass weight.

[0065] In one implementation, biomass has a weight, and a waste product of the biomass is less than 15% of the biomass weight.

[0066] In another implementation, the method further comprises the step of producing energy utilizing the waste product.

[0067] In still another implementation, a method for biorefining comprises the steps of providing biomass, processing the biomass to provide a plurality of component streams resulting in at least one waste product, and utilizing at least one waste product to produce energy.

[0068] In yet another implementation, the energy is heat or power.

[0069] In still yet another implementation, the method for biorefining comprises the steps of providing woody biomass, agricultural biomass, and cultivated plant biomass; providing the woody biomass comprising at least one biomass of softwood trees, softwood shrubs, softwood bushes, hardwood trees, hardwood shrubs, hardwood bushes, hybrid trees, hybrid shrubs, hybrid bushes, cultivated trees, cultivated shrubs, cultivated bushes, forest trees, forest shrubs, forest bushes; providing the woody biomass comprising of at least one biomass of recycled wood, recovered wood, recycled wood products, and recovered wood products;
providing the agricultural biomass comprising at least one biomass of agricultural plants, annual agricultural plants, perennial agricultural plants, biennial agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, genetically modified annual agricultural SUBSTITUTE SHEET (RULE 26) plants, native perennial agricultural plants, hybrid perennial agricultural plants, genetically modified perennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants;
providing the agricultural biomass comprising at least one agricultural residues of agricultural plants, annual agricultural plants, perennial agricultural plants, biennial agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, genetically modified annual agricultural plants, native perennial agricultural plants, hybrid perennial agricultural plants, genetically modified perennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants;
providing the cultivated plant biomass comprising at least one biomass of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, and grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants; providing the cultivated plant biomass comprising at least one cultivated plant residues of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants; processing the biomass using mechanical processing, component separation processing, optional chemical processing, residual chemical removal, and an additional treatment; providing a plurality of component streams comprising lignin, cellulose, and hemicellulose from the biomass; recovering chemicals used in the optional chemical processing and the residual chemical removal for recycling; removing extractables from the optional chemical processing and the additional treatment; reducing a waste product of the biomass, wherein the biomass has a weight, and the waste product of the biomass is less than 25% of the biomass weight; producing energy utilizing the waste product;
producing at least one product of commodity chemicals, fine chemicals, and specialty chemicals;

SUBSTITUTE SHEET (RULE 26) and producing at least one product of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, pyrolytic oils, cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, ethanol, furans, dihydrofurans, tetrahydrofurans, lactones, and butenes from at least one of the component streams.

[0070] Further, the method described herein provides a method for biorefining that is easy to implement and use.

[0071] To the accomplishment of the foregoing and related ends, the following description and annexed drawings set forth certain illustrative aspects and implementations.
These are indicative of but a few of the various ways in which one or more aspects may be employed. Other aspects, advantages and novel features of the disclosure will become apparent from the following detailed description when considered in conjunction with the annexed drawings.
III. Brief Description of the Drawings [0072] What is disclosed herein may take physical form in certain parts and arrangement of parts, and will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:

[0073] FIGURE 1 is a flow diagram schematically illustrating what is disclosed herein.

[0074] FIGURE 2 is a flow diagram schematically illustrating what is disclosed herein.

[0075] FIGURE 3 is a flow diagram schematically illustrating what is disclosed herein.

[0076] FIGURE 4 is a flow diagram schematically illustrating what is disclosed herein.

[0077] FIGURE 5 is a flow diagram schematically illustrating what is disclosed herein.

SUBSTITUTE SHEET (RULE 26) [0078] FIGURE 6 is a flow diagram schematically illustrating what is disclosed herein.

[0079] FIGURE 7 is a flow diagram schematically illustrating what is disclosed herein.
IV. Detailed Description [0080] Referring now to the drawings wherein the showings are for purposes of illustrating embodiments of the invention only and not for purposes of limiting the same.
Relative language used herein is best understood with reference to the drawings, in which like numerals are used to identify like or similar items.

[0081] Biomass is made up primarily of cellulose, hemicellulose, and lignin.
These components, if economically separated from one another, can provide vital sources of chemicals normally derived from petrochemicals. The use of biomass can also be beneficial with plants that are sparsely used and by-products, residues and plant wastes that currently have little or no use. Biomass can provide valuable chemicals and reduce dependence on coal, gas, and fossil fuels, in addition to boosting local and worldwide economies. Biomass can include agricultural biomass, woody biomass, and cultivated plant biomass. Agricultural biomass can be considered to be plants, roots, leaves, stems, stocks, seeds, fruits, nuts, or other products of agriculture.
Agricultural residues may include stover, straw, hay, bagasse, hulls, straw, nut shells, crop residues, and clippings and prunings from orchards and vineyards. Woody biomass may include wood, wood by-products, wood residues, and wood wastes. Cultivated plant biomass can be comprised of plants whose origin or selection is primarily due to intentional human activity.

[0082] Biomass is also plentiful throughout the United States and the world.
For example, some estimates of the amount of sustainably harvestable forest biomass in the United States alone are about 370 million dry tons per annum, a small fraction of the total timberlands inventory of more than 20 billion dry tons. Also, some estimates of the agricultural biomass in the United States are about 1 billion tons annually with about 200 million tons of that amount in agricultural residues. Another aspect of biomass is that it is often a by-product, residue or waste product of other processes, such as farming, forestry, landscaping, timber and the pulp and paper industry, and the biomass and biomass residues are underutilized and left to rot or are burned.

SUBSTITUTE SHEET (RULE 26) Instead of creating a waste product, biomass can provide valuable chemicals and reduce dependence on coal, gas, and fossil fuels, in addition to boosting local and worldwide economies.
Additionally, there are several other benefits to using biomass. Some of these benefits may include reducing the threat and impact of wildfires on communities, improving recreation and scenic opportunities by thinning overcrowded forests, improving human health through better air quality and reduced wildfire and prescribed fires emissions, providing rural community vitality though the provision of sustainable environments and economies over the long term, providing increased societal awareness by using forest restoration activities as a learning tool to promote wise forest management, and lowering treatment costs by finding new markets for removed residue. Some of the ecological and environmental benefits may include decreasing insect and disease outbreaks toward endemic levels, decreasing unnaturally severe fires within forests and grasslands, facilitating the removal of invasive woody species, increasing ability to protect and restore critical wildlife habitat, providing clean air through decreased wildfires size and severity, increasing the longevity of landfills which reduces the amount of land that needs to be converted into new landfills, improving vigor of remaining trees, reducing fire related erosion and maintain healthy watersheds, improving forest health, reducing dependence on fossil fuels, reducing greenhouse gas emissions, and reducing atmospheric concentrations of greenhouse gases through substitution of fossil fuels energy when woody biomass is regrown. Economic benefits may include providing new jobs and income through new biomass industries, decreasing energy costs by substituting woody biomass for other fuels, providing private land owners opportunities for carbon market income by growing short rotation woody crops for energy, lessening the potential of wildfire near communities, reducing cost of treatment for land managers, providing employment and economic stability to rural, forest-dependent communities, attracting investments in new industry and markets and stabilizing existing markets including tourism, complementing traditional utilization of higher values wood products, avoiding fire suppression and resource damage costs of wildfires, and increasing capacity to pursue new management incentives and opportunities such as emission reduction credits in energy production.

[0083] The use of biomass in the production of chemicals historically has focused mostly on bioethanol and biodiesel. Cellulosic bioethanol production requires a breakdown of the biomass into component streams with often only the cellulose component utilized. The SUBSTITUTE SHEET (RULE 26) OrganoSolvu\'I and Alcell processes can be used to efficiently separate cellulose from biomass under mild conditions, namely through the use of an aqueous organic solvent, usually ethanol.
These processes provide the simultaneous removal of the hemicellulose sugar and lignin in separated streams. Even though an organic solvent is used during this process, it can be recycled and used again in the process. Alternatively, separate component streams can be obtained from biomass through at least one known process of kraft pulping, sulfite pulping, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, enzymatic hydrolysis, pyrolytic processes, and enzymatic treatment.
Of these, the kraft pulping of woody biomass is by far the dominant chemical pulping method practiced across the world today.

[0084] Although the cellulosic fraction of biomass has garnered attention as a feedstock for bioethanol and solid biofuel, the intrinsic value of the other components of biomass in chemical production continues to be largely overlooked. Other than fossil fuels, lignin is an abundant source of aromatic chemicals. Lignin can be used in developing technologies that transform biomass into value-added, aromatic chemicals. In addition, the cellulose and hemicellulose portions of biomass can also be converted into useful biobased chemicals.

[0085] FIGURE 1 shows a flow diagram schematically depicting the general overview for the illustrative flow for a method for treating and processing biomass 10 for production of biobased chemicals 40. First, biomass 10 may be obtained for processing.
Biomass 10 refers to any plant derived organic matter, whether native, non-native, or hybrid.
Biomass 10 may be used for the production of biobased chemicals 40. Biomass 10 can include woody biomass, agricultural biomass, cultivated plant biomass, and any plant biomass. Biomass 10 can be received in any number of forms, including loose, bailed, wrapped, pellets, cubes, and briquettes.

[0086] Specific types of biomass 10, namely woody biomass, agricultural biomass, and cultivated plant biomass, may include different forms. First, woody biomass 10 may include limbs, tops, needles, leaves, and other woody parts, grown in a forest, woodland, or rangeland environment, that are the by-products of forest management. Woody biomass 10 can also include but is not limited to logs, wood chips, wood bark, wood powder, sawdust, pulp products, SUBSTITUTE SHEET (RULE 26) wood pellet products, sawmill products, salvaged wood products, logging waste, forest products, and wood products. Sources of woody biomass 10 can encompass both native and cultivated trees including hybrids. The woody biomass 10 may include softwood trees, softwood shrubs, and softwood bushes. This woody biomass 10 may include hardwood trees, hardwood shrubs, and hardwood bushes. Additionally, the woody biomass 10 may include hybrid trees, hybrid shrubs, and hybrid bushes. Woody biomass 10 can also include native trees, forest trees, native shrubs, forest shrubs, native bushes, and forest bushes. Woody biomass 10 may also include residential or commercial landscaping trees, shrubs, and bushes. The woody biomass 10 may include recycled and/or recovered wood and wood products. Second, agricultural biomass 10 can include but is not limited to agricultural food and feed crops, whether or not hybrid or genetically modified, agricultural products, and agricultural residues like stover, hay, straw, prunings, and clippings. Agricultural biomass 10 can be considered to contain plants, leaves, stems, stalks, roots, seeds, fruits, nuts, or other products of agriculture.
Some types of agricultural biomass 10 may include agricultural biomass that is annual, biennial, or perennial.
Agricultural biomass 10 can also contain an agricultural residue product of agricultural biomass.
These agricultural residues from the agricultural biomass 10 may include stover, straw, hay, bagasse, hulls, straw, nut shells, crop residues, and clippings and prunings from orchards and vineyards. Third, cultivated biomass 10 can include but is not limited to cultivated crop plants like switchgrass, miscanthus and sweet sorghum that may be grown for the production of fuels and chemicals. Cultivated plant biomass 10 can be comprised of plants whose origin or selection is primarily due to intentional human activity. Some examples of cultivated plant biomass 10 can include but are not limited to cultivated plants like switchgrass, miscanthus, hemp, King grass, sugarcane, sweet sorghum, duckweed, and a variety of cultivated tree species ranging from eucalyptus to palm oil. Some of this cultivated plant biomass 10 may be grown for the production of fuels and chemicals. Because of their typical higher biomass density per acre, cultivated plant biomass 10 may provide a biomass source where they are utilized, particularly in geographies and/or soils where certain higher value agricultural and woody biomass do not grow as well. In other words, cultivated plant biomass 10 may provide a use for marginal lands where environmental stress is inherent and the land cannot be used for typical agricultural or timber purposes. In the process described herein, this cultivated plant biomass 10 may be used for the production of biobased chemicals 40. The cultivated plant biomass 10 may be considered to SUBSTITUTE SHEET (RULE 26) include cultivated plants, cultivated trees, cultivated shrubs, and cultivated bushes. Sources of cultivated plant biomass 10 can encompass native plants, hybrid plants, and genetically modified plants. In addition, cultivated plant biomass 10 may include annual cultivated plants. native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants. Cultivated plant biomass 10 may also include residential landscaping plants and commercial landscaping plants. Cultivated plant biomass 10 may include some agricultural plants, medicinal plants, fiber plants, ornamental plants, aquatic plants, and grassy plants. The cultivated plant biomass 10 described herein can also be a by-product, residue or waste product of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants.

[0087] In essence, biomass 10 may include any plant based source that can be added to the process to create at least one component stream, typically lignin 34, cellulose 26, and hemicellulose 36, for the production of biobased chemicals 40. Depending on the type of biomass 10 material, the amounts of the biomass 10, and the compositions of the biomass 10, these component streams can differ.

[0088] Next, the biomass 10 may undergo a mechanical processing 12 in order to reduce the size of the biomass 10 and prepare it for further processing. For the mechanical processing 12, the biomass 10 can undergo chopping, chipping, cutting, shredding, debarking, milling, and grinding. In order to break down the biomass, there can be one or more mechanical processing 12 steps needed. The type of mechanical processing 12 may be dependent upon the type of biomass 10 and its requirements for breaking it down for further treatment.

SUBSTITUTE SHEET (RULE 26) [0089] After the mechanical processing 12, the biomass 10 may be subjected to an optional chemical processing 14. This optional chemical processing 14 may serve to further break down the biomass 10 as well as remove fats, oils, resins, pitches, waxes, and other extractables. After both mechanical processing 12 and optional chemical processing 14, a biomass fractionation 16 can be formed.

[0090] Still referring to FIGURE 1, the biomass fractionation 16 may undergo a first filtration 18 if the optional chemical processing 14 is completed. The first filtration 18 serves to remove the optional chemical processing 14 from the biomass fractionation 16.
The fats, oils, resins, pitches, waxes, and other extractables removed in the optional chemical processing 14 can be further separated during the first filtration 18 and marketed as useful products of commerce.
From the first filtration 18, the chemical used from the optional chemical processing 14 can be recycled under a chemical recycling 38 step. This chemical recycling 38 process will be detailed further in FIGURE 7.

[0091] Using the biomass fractionation 16 step can provide a greener process by utilizing at least three of the component streams of biomass 10. These three component streams of biomass 10 may include cellulose 26, hemicellulose 36, and lignin 34.
Typically for woody biomass 10, the cellulose 26 may be about 39% to about 57%, the hemicellulose 36 may be about 8% to about 28%, and the lignin 34 may be about 15% to about 28%.
Depending on the different species of woody biomass 10, these ratios can vary. For hardwood woody biomass 10.
the hemicellulose 36 amounts can be higher. For softwood woody biomass 10, the lignin 34 amounts and the cellulose 26 amounts can be higher. In looking at the ranges for agricultural biomass 10, the cellulose 26 may be about 30% to about 42%, the hemicellulose 36 may be about 12% to about 39%, and the lignin 34 may be about 11% to about 29%.
Different species of agricultural biomass 10, like woody biomass 10, can also vary for these ratios. Likewise, for cultivated plant biomass 10, the amounts of cellulose 26, hemicellulose 36, and lignin 34 will vary for different species of cultivated plant biomass 10. Depending on the type of biomass 10 used or targeted, the amounts of each of the component streams can determine the end products in the production of biobased chemicals 40.

SUBSTITUTE SHEET (RULE 26) [0092] After the first filtration 18 with the optional chemical processing 14, the filtered biomass fractionation 20 may be formed. Either the filtered biomass fractionation 20 from the optional chemical processing 14 or the biomass fractionation 16 from the mechanical processing 12 alone can be broken down even further by component separation processing 22. In the component separation processing 22, a high pressure and temperature can successfully break down the biomass even further. Alternatively, the filtered biomass fractionation 20, or the biomass fractionation 16 from the mechanical processing 12 alone, can be broken down with other processes in the component separation processing 22 that may include at least one of kraft pulping, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment. A second filtration 24 can then be done to separate the cellulose 26 from the lignin and hemicellulose mixture 28. This lignin and hemicellulose mixture 28 can then go through both a residual chemical removal 30 and a third filtration 32 in order to separate the lignin and hemicellulose mixture 28 into lignin 34 and hemicellulose 36. Further, an optional pH
adjustment 50 may take place prior to the third filtration 32 to effect a more complete separation of lignin 34 and hemicellulose 36. With the separated component streams for cellulose 26, lignin 34, and hemicellulose 36, the production of biobased chemicals 40 can be achieved.

[0093] FIGURE 2 is a flow diagram schematically depicting the process in which biomass 10 may be mechanically and optionally chemically processed to provide both a fractionated and filtered biomass product in accordance with an embodiment of the present invention.

[0094] In FIGURE 2, the biomass 10 may undergo mechanical processing 12 in order to reduce the size of the biomass 10 and prepare it for further processing.
For the mechanical processing 12, the biomass 10 can be delivered for processing. Depending on the type of biomass 10, the mechanical processing 12 can vary. The mechanical processing 12 can include chopping, chipping, cutting, shredding, debarking, milling, and grinding. For example, logs and branches of woody biomass may undergo one or more of debarking, chopping, chipping, milling and grinding. Sawdust can also undergo additional mechanical processing, but would have been SUBSTITUTE SHEET (RULE 26) subjected to previous mechanical processing. However, agricultural biomass such as corn stover or cultivated plant biomass like miscanthus, switchgrass and sweet sorghum are fibrous materials, and may only require one or more of chopping, cutting, shredding, milling and grinding. No matter what type of biomass 10 may be used, milling or chopping may be needed in order to reduce size of the material for ease and efficiency of processing.
The biomass 10 can be milled to various sizes, but the size of the milled biomass is tied to the efficiency of how it is broken down within the subsequent processes. For instance, larger particle sizes of milled biomass may take longer to be broken down in both the optional chemical processing 14 and later processes within the component separation processing 22 due to less surface area in which to react during the breakdown processes. Wood and agricultural biomass 10 can typically be milled to a particle diameter of less than I/8". The maximum particle diameter for milling of woody biomass 10 can typically be about 1/4". Other sources of biomass 10 such as agricultural stover can be processed using particle sizes longer than I/8" because the thin fiber widths of such biomass 10 like stover provide greater surface area for reaction than a rounder particle of the same length. Preferably, a uniform particle size or thin fiber length can be reached for ease and consistency of processing during the subsequent processes.

[0095] After the mechanical processing 12, the biomass 10 may be subjected to an optional chemical processing 14. Biomass 10 may undergo the optional chemical processing 14 if additional breakdown of the biomass 10 is needed. Some biomass 10, like agricultural stover.
may not require optional chemical processing 14 since it may be sufficiently broken down with mechanical processing 12 alone. Some types of biomass 10, like trees, may benefit from the optional chemical processing 14 in the production of biobased chemicals 40.
This optional chemical processing 14 may typically be done through a solvent treatment.
During the optional chemical process 14, the biomass 10 can be further broken down after the mechanical processing 12. Typically, the optional chemical processing 14 can be performed in a solvent like ethanol.
Besides ethanol, other organic solvents, acids, bases, or enzymes can be used for the optional chemical processing 14. However, the use of these acids, bases, or enzymes may lead to varying degrees of hydrolysis.
SUBSTITUTE SHEET (RULE 26) [0096] The optional chemical processing 14 can also undergo an optional extractables removal 52. The optional extractables removal 52 helps to remove any extractables from the biomass 10. Some of these extractables can include fats, oils, resins, pitches, and waxes present in different forms of biomass. Depending on the biomass source, the type and amount of these extractables can vary. The extractables do not have to be taken out, but their removal may allow for a purer end product with the production of biobased chemicals 40 in FIGURE
1. Further, the optional extractables removal 52 may provide products of importance to commerce and for more of a comprehensive utilization of the biomass resource and generation of less waste. The extractables removed during the optional extractables removal 52 can be further separated, processed, and marketed as useful products of commerce for at least one of biofuels, lubricants, cleaning agents, disinfectants, deodorant additives, scents, and extraction of metal from ores.

[0097] After both mechanical processing 12 and optional chemical processing 14, the biomass fractionation 16 may be formed. The biomass fractionation 16 can then filtered to form the filtered biomass fractionation 20 if it was subjected to optional chemical processing 14. In this filtration after the mechanical and chemical processing, which is referred to as the first filtration 18, the optional chemical processing 14 can be partially removed from the biomass fractionation 16. For the first filtration 18, there are a series of steps where the biomass fractionation 16 may be filtered, then washed with additional chemical which is used in the optional chemical processing 14, typically ethanol or another alcohol, and then filtered again to remove some of the chemical from the optional chemical processing 14. After the wash and first filtration 18, typically about 50% of the chemical may be removed. The filtered biomass fractionation 20 may or may not contain some of the chemical from the optional chemical processing 14 step. From this step, either the filtered biomass fractionation 20 or the biomass fractionation 16 will be subjected to the component separation processing 22 as detailed in FIGURE 3.

[0098] With reference now to FIGURE 3, the flow diagram schematically depicts the process in which the biomass fractionation 16 or the filtered biomass fractionation 20 may be processed further to obtain a treated biomass fractionation 42 in accordance with an embodiment of the present invention. The biomass fractionation 16 or the filtered biomass fractionation 20 SUBSTITUTE SHEET (RULE 26) can be subjected to a component separation processing 22. The component separation processing 22 may include a high pressure and temperature treatment to form the treated biomass fractionation 42. The pressure can be generated and controlled by heating in a sealed vessel.
The pressure typically ranges from about 100 psi to about 800 psi. The temperature can range from about 150 C to about 300 C (about 300 F to about 572 F), with about 200 C to about 250 C (about 392 F to about 482 F) typically used. The high pressure and temperature treatment can be conducted in a solvent, generally under alkaline conditions.
Often, an ethanol and water mixture may be used as the solvent. Other alcohols or water mixtures may also be used in component separation processing 22. The high pressure and temperature treatment may serve to breakdown and solubilize the hemicellulose and lignin components of biomass. Because both the hemicellulose and lignin are solubilized, the lignin and hemicellulose mixture 28 can be later separated from the insoluble cellulose 26. Also, extractables may be removed and recovered/recycled from this treatment as well as any chemicals like alcohols.

[0099] After the high pressure and temperature treatment, a treated biomass fractionation 42 may then be attained. Alternatively, the biomass fractionation 16 or filtered biomass fractionation 20 can also be broken down with other processes in the component separation processing 22 that may include at least one of kraft processing, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment. No matter what process is used within the component separation processing 22, the biomass can be broken down to the treated biomass fractionation 42 after the component separation processing 22 is completed.
During the component separation processing 22, the hemicellulose component may hydrolyze the easiest whereas cellulose may be the most difficult to hydrolyze. The hydrolyzation difference in the method described herein can help to separate the component streams of the biomass. From the hydrolysis, a physical division of the component streams may occur.

[0100] From there, the second filtration 24 can be done on the treated biomass fractionation 42 in order to separate the cellulose 26 from the lignin and hemicellulose mixture 28. The second filtration 24 serves to remove the insoluble cellulose 26 from the soluble lignin and hemicellulose mixture 28. Optionally, the insoluble cellulose 26 can be washed with water SUBSTITUTE SHEET (RULE 26) or a chemical like aqueous ethanol and separated from the wash in the second filtration 24. The filtration leaves an aqueous mixture of hemicellulose sugars and solubilized lignin. The residual chemical(s) can be removed from this filtrate through concentration or distillation by applying a low to modest temperature and a minimal vacuum which may be sufficient to evaporate the chemical in the residual chemical removal 30 of FIGURE 1. When the chemical is ethanol, this temperature may be about 25 C to about 40 C (about 77 F to about 104 F) and the pressure typically may vary from about 30 millimeters of mercury to about 70 millimeters of mercury.
The chemical may then be recycled for reuse. Ideally, 100% of the chemical would be recovered so that it can be recycled back into the process, which reduces costs associated with purchasing additional chemicals. Typically, at least 90% may be recovered for recycling.
The second filtration 24 also can assist in separating the solubilized lignin and hemicellulose mixture 28 from the insoluble and solid cellulose 26. After this step, the separated cellulose 26 can undergo the production of biobased chemicals 40.

[0101] FIGURE 4 is a flow diagram schematically depicting the process in which the treated biomass fractionation 42 can provide cellulose 26, which may be further processed to produce derivative products in accordance with an embodiment of the present invention. In separating the cellulose 26 after the second filtration 24, the cellulose 26 can then be processed to allow for the production of biobased chemicals 40. The second filtration 24 also may provide a way to obtain the soluble lignin and hemicellulose mixture 28. For instance, the cellulose 26 can be hydrolyzed, reacted, and purified to provide for the production of biobased chemicals 40, namely cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, furans, dihydrofuran, tetrahydrofurans, lactones, and ethanol. Some of these biobased chemicals from cellulose 26 can include but are not limited to cellulose acetate, cellulose propionate, cellulose benzoate, methyl and ethyl adipate, methyl and ethyl levulinate, methyl and ethyl succinate, methyl and ethyl 2,5-furandicarboxylate, adipic acid, levulinic acid, succinic acid, 2,5-furandicarboxylic acid, 3,4-dehydro-y-valerolactone, 7-valerolactone, 2-methyltetrahydrofuran, sorbitol, hexane-1,6-diol, pentane-1,4-diol, butane-1,4-diol, 2,5-di(hydroxymethyl)furan, 2,5-di(hydroxymethyl)tetrahydrofuran, glyercol, propylene glycol, and ethanol.

SUBSTITUTE SHEET (RULE 26) [0102] FIGURE 5 is a flow diagram schematically depicting the treated biomass fractionation 42 which can be further processed to obtain lignin 34 and hemicellulose 36 in accordance with an embodiment of the present invention. After the treated biomass fractionation 42 is subjected to a second filtration 24, the lignin and hemicellulose mixture 28 may be attained.
From this step, the residual chemical removal 30 can then be completed. In addition to chemicals added during the component separation processing 22 shown in FIGURE
3, the residual chemical removal 30 can remove any chemicals carried over from the optional chemical processing 14 shown in FIGURE 2, which may also be recycled back into the process. In the residual chemical removal 30, a chemical, typically an alcohol like ethanol can be recovered through concentration or distillation by applying a low to modest temperature and a minimal vacuum which may be sufficient to evaporate the alcohol in the residual chemical removal 30.
When the alcohol is ethanol, this temperature may be about 25 C to about 40 C (about 77 F to about 104 F) and the pressure typically may vary from about 30 millimeters of mercury to about 70 millimeters of mercury. The chemical may then be recovered and recycled for reuse. After a third filtration 32, the mixture can then be separated into lignin 34 and hemicellulose 36. In some instances, the processing may require the optional pH adjustment 50 using an acid to adjust the pH of the solution to a point which the lignin and hemicellulose can be efficiently separated from each other prior to the third filtration 32. Typically, sulfuric acid can be used in the optional pH adjustment 50, but other acids may be employed. Optionally, the precipitated lignin can be washed with water and separated from the wash in the third filtration 32. In the third filtration 32, the hemicellulose 36 can be primarily soluble and may be in an aqueous solution of the filtrate. The optional removal of the water from the hemicellulose 36 provides a concentrated form of hemicellulose sugars. The separation of the component streams to lignin 34 and hemicellulose 36 can permit the production of biobased chemicals 40. Lignin 34 can be a source of aromatic chemicals like aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, and pyrolytic oils. Some of the specific biobased chemicals from lignin 34 can include but are not limited to methyl and ethyl 4-hydroxybenzoate, methyl and ethyl vanillate, methyl and ethyl syringate, 4-hydroxybenzoic acid, (4-hydroxyphenyl)acetic acid, vanillic acid, homovanillic acid, syringic acid, homosyringic acid, 4-hydroxybenzaldehyde, vanillin, syringaldehyde, 4-hydroxybenzyl alcohol, 2-(4-hydroxyphenyl)ethanol, vanillyl alcohol, SUBSTITUTE SHEET (RULE 26) homovanillyl alcohol, syringyl alcohol, homosyringyl alcohol, 4-hydroxyacetophenone, acetoguaiacone, acetosyringone, 4-hydroxystyrene, 3-methoxy-4-hydroxystyrene, 3,5-dimethoxy-4-hydroxystyrene, (4-hydroxypheny1)-1-propene, (4-hydroxypheny1)-2-propene, eugenol, iso-eugenol, syringeugenol, iso-syringeugenol, ethyl phenol, ethyl guaiacol, ethyl syringol, propyl phenol, propyl guaiacol, propyl syringol, cresol, creosol, syringyl creosol, phenol, guaiacol, syringol, benzene, toluene, xylene, ethyl benzene, propyl benzene, biphenyl, and pyrolytic oils. Hemicellulose 36 can provide furans, dihydrofurans, tetrahydrofurans, polyols, lactones, and butenes. Some of the specific biobased chemicals from hemicellulose 36 may include but are not limited to furfural, y-butyrolactone, tetrahydrofuran, ribitol, xylitol, arabitol, glyercol, propylene glycol, and isoprene.

[0103] FIGURE 6 is a diagram schematically depicting the plurality of the component streams and their conversion to derivative biobased products in accordance with an embodiment of the present invention. It shows the production of some derivative products from the plurality of component streams, namely cellulose 26, lignin 34, and hemicellulose 36.
The processes described herein may provide only one independent and separate component stream or a plurality of component streams. These derivative biobased product(s) may be obtained from only one independent and separate component stream or more that one of the component streams. Each component stream may provide only one derivative product or more than one derivative product, which may also be used in the production of another chemical or other chemicals. A derivative product or a plurality of derivative products may be commodity, fine, and/or specialty chemicals, and be produced through at least one of chemical processing, biological processing, catalytic processing, and/or pyrolytic processing. These products can be at least one of aromatic chemicals, aliphatic chemicals, heterocyclic chemicals, and fuels. These products can be at least one of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, pyrolytic oils, cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, ethanol, furans, dihydrofuran, tetrahydrofurans, lactones, ethanol, and butenes. For example, aliphatic carboxylic acids may include but are not limited to adipic acid, levulinic acid and succinic acid.
For instance, polyols may include but are not limited to sorbitol, xylitol, arabinitol, hexane-1,6-diol, pentane-1,4-diol, butane-1,4-diol, 2,5-hydroxymethylfuran, 2,5-SUBSTITUTE SHEET (RULE 26) hydroxymethyltetrahydrofuran, glyercol, propylene glycol. For example, aromatic aldehydes may include but are not limited to 4-hydroxybenzaldehyde, vanillin, and syringealdehyde. For instance, benzenes may include benzene, toluene, xylene, and biphenyl. Since the process can generate a plurality of component streams which may then be used for the production of biobased chemicals, waste can be minimized. The residual biomass waste from this process can be less than 25%. It can also be less than 15%. The waste from the process may also be used to produce energy, including heat and/or power. This method for reducing waste can provide greener process where the majority of the biomass provided at the beginning of the process can be converted into usable products in the production of biobased chemicals.

[0104] FIGURE 7 is a flow diagram schematically depicting an illustrative flow of the biomass treatment and processing along with the recovery of chemicals 44 used within the process in accordance with an embodiment of the present invention. In this diagram, the chemicals used for treating the biomass 10 in the optional chemical processing 14, the first filtration 18, the component separation processing 22, and the second filtration 24 can be recoverable and recyclable for reuse. First, the biomass 10 may undergo a mechanical processing 12. After the optional chemical processing 14, the biomass fractionation 16 can be formed. Then, the first filtration 18 may be performed. Typically, the chemical for the optional chemical processing 14 is an alcohol like ethanol. After the first filtration 18, there may be a recovery of chemicals 44 in which the chemical can be removed from the filtered biomass fractionation 20. Besides the recovery of chemicals 44 from the first filtration 18, the analogous recovery of chemicals 44 may be applicable from the residual chemical removal 30. From the recovery of chemicals 44, the chemical may be subjected to a distillation and/or filtration 46, and can then be placed into a chemical holding tank 48 for reuse in one or more of the optional chemical processing 14, the washes of the first filtration 18, the component separation processing 22, or the washes of the second filtration 24 steps. Ideally, 100% of the chemicals used in the process would be recovered. Preferably, at least a 90% recovery can provide a greener process where fewer chemicals are used and costs associated with purchasing more chemicals from the recovery loss are minimized. Additionally, during this process, the recovery of chemicals from the component stream can be processed to derivative products.

SUBSTITUTE SHEET (RULE 26) [0105] The flow diagrams depicted herein are provided merely as an example to clearly and concisely describe embodiments of the method within the scope of the present invention.
Some steps may be skipped or modified, new steps may be added, existing steps may be deleted, or the order of steps may be altered from that shown in the flow diagrams without departing from the scope of the present invention. It will be apparent to those skilled in the art that the above methods may incorporate changes and modifications without departing from the general scope of the appended claims or the equivalents thereof. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.

SUBSTITUTE SHEET (RULE 26)

Claims

1. A method for biorefining, comprising the steps of:
providing biomass;
processing said biomass to provide a plurality of component streams; and producing derivative products from said plurality of component streams.

2. The method of claim 1, wherein said biomass comprises plant biomass.

3. The method of claim 2, wherein said plant biomass comprises woody biomass, agricultural biomass, and cultivated plant biomass.

4. The method of claim 3, wherein said woody biomass comprises at least one softwood biomass of softwood trees, softwood shrubs, and softwood bushes.

5. The method of claim 3, wherein said woody biomass comprises at least one hardwood biomass of hardwood trees, hardwood shrubs, and hardwood bushes.

6. The method of claim 3, wherein said woody biomass comprises at least one hybrid biomass of hybrid trees, hybrid shrubs, and hybrid bushes.

7. The method of claim 3, wherein said woody biomass comprises at least one forest biomass of forest trees, forest shrubs, and forest bushes.

8. The method of claim 3, wherein said woody biomass comprises at least one biomass of recycled wood, recovered wood, recycled wood products, and recovered wood products.

9. The method of claim 3, wherein said agricultural biomass comprises at least one agricultural biomass of agricultural plants, annual agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, and genetically modified annual agricultural plants.

10. The method of claim 3, wherein said agricultural biomass comprises at least one perennial agricultural biomass of perennial agricultural plants, native perennial agricultural plants, hybrid perennial agricultural plants, and genetically modified perennial agricultural plants.

11. The method of claim 3, wherein said agricultural biomass comprises at least one biennial agricultural biomass of biennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants.

12. The method of claim 3, wherein said agricultural biomass comprises of at least one agricultural residue of agricultural plants, annual agricultural plants, perennial agricultural plants, biennial agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, genetically modified annual agricultural plants, native perennial agricultural plants. hybrid perennial agricultural plants, genetically modified perennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants.

13. The method of claim 3, wherein said cultivated plant biomass comprises at least one biomass of cultivated plants, cultivated trees, cultivated shrubs, and cultivated bushes.

14. The method of claim 3, wherein said cultivated plant biomass comprises at least one cultivated plant of aquatic plants, medicinal plants, fiber plants, ornamental plants, and grassy plants.

15. The method of claim 3, wherein said cultivated plant biomass comprises at least one annual cultivated plant of annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, and genetically modified annual cultivated plants.

16. The method of claim 3, wherein said cultivated plant biomass comprises at least one perennial cultivated plant of perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, and genetically modified perennial cultivated plants.

17. The method of claim 3, wherein said cultivated plant biomass comprises at least one biennial cultivated plant of biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants.

18. The method of claim 3, wherein said cultivated plant biomass comprises cultivated plant residues of at least one of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants.

19. The method of claim 1, wherein said plurality of component streams comprises lignin, cellulose, and hemicellulose.

20. The method of claim 1, wherein said step of processing said biomass to provide a plurality of component streams comprises mechanical processing and component separation processing.

21. The method of claim 20, wherein said mechanical processing comprises at least one mechanical process of chopping, chipping, cutting, shredding, debarking, milling, and grinding.

22. The method of claim 20, wherein said biomass is woody biomass and said processing of said woody biomass by said mechanical processing comprises at least one of mechanical process of debarking, chopping, chipping, milling, and grinding.

23. The method of claim 20, wherein said biomass is agricultural biomass or cultivated plant biomass and said processing of said plant biomass by said mechanical processing comprises at least one of chopping, cutting, shredding, milling, and grinding.

24. The method of claim 20, wherein said step of component separation processing further comprises the step of:
providing cellulose.

25. The method of claim 20, wherein said component separation processing comprises at least one component of lignin and hemicellulose.

26. The method of claim 20, wherein said step of processing said biomass to provide a plurality of component streams, further comprises the step of:
completing a chemical processing during said processing of said biomass.

27. The method of claim 26, wherein said chemical processing comprises at least one treatment of solvent treatment, acidic treatment, basic treatment, and enzymatic treatment.

28. The method of claim 26, further comprising the step of:
removing extractables from said chemical processing.

29. The method of claim 28, wherein said step of removing extractables from said chemical processing further comprises the step of at least one process of:
extracting metals from ore, lubricating, cleaning, disinfecting, deodorizing, scenting, and producing biofuels.

30. The method of claim 26, further comprising the steps of:
recovering chemicals from said chemical processing; and recycling said chemicals from said chemical processing.

31 31. The method of claim 20, further comprising the step of:
using a residual chemical removal in said step of processing said biomass.

32. The method of claim 31, wherein said step of using residual chemical removal produces hemicellulose and lignin.

33. The method of claim 31, wherein said step of using residual chemical removal further comprises the steps of:
adjusting a pH; and producing hemicellulose and lignin.

34. The method of claim 31, further comprising the steps of:
recovering at least one chemical from said residual chemical removal; and recycling said at least one chemical from said residual chemical removal.

35. The method of claim 20, wherein said step of processing said biomass to provide a plurality of component streams further comprising the step of:
utilizing an additional treatment during said processing of said biomass.

36. The method of claim 35, wherein said additional treatment comprises at least one treatment of heat treatment, pressure treatment, kraft pulping, sulfite pulping, pyrolysis, steam explosion, ammonia fiber explosion, dilute acid hydrolysis, alkaline hydrolysis, alkaline oxidative treatment, and enzymatic treatment.

37. The method of claim 36, further comprising the step of selectively utilizing at least two of said additional treatments during said processing of said biomass.

38. The method of claim 36, further comprising the step of removing extractables from said additional treatment.

39. The method of claim 36, further comprising the steps of:

recovering at least one chemical from said additional treatment; and recycling said at least one chemical from said additional treatment.

40. The method of claim 1, further comprising the step of selectively utilizing one of said component streams for producing said derivative products.

41. The method of claim 1, further comprising the step of selectively utilizing at least two of said component streams for producing said derivative products.

42. The method of claim 1, wherein said plurality of component streams is a mixture of said component streams.

43. The method of claim 1, wherein at least one component stream of said plurality of component streams is an independent and separate component stream from said plurality of component streams.

44. The method of claim 43, further comprising the step of selectively producing one derivative product from said independent and separate component stream.

45. The method of claim 43, further comprising the step of selectively producing at least two derivative products from said independent and separate component stream.

46. The method of claim 1, further comprising the step of producing at least one derivative product from a residue component stream.

47. The method of claim 1, wherein said derivative products comprises at least one product of commodity chemicals, fine chemicals, and specialty chemicals.

48. The method of claim 1, wherein said producing derivative products comprises at least one process of chemical processing, biological processing, catalytic processing, and pyrolytic processing.

49. The method of claim 1, wherein one of said component streams is lignin, and said derivative products from lignin comprise at least one product of aromatic chemicals and fuels.

50. The method of claim 49, wherein said derivative products from lignin comprise at least one product of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, and pyrolytic oils.

51. The method of claim 49, wherein said derivative products from lignin comprise at least one product of methyl and ethyl 4-hydroxybenzoate, methyl and ethyl vanillate, methyl and ethyl syringate, 4-hydroxybenzoic acid, (4-hydroxyphenyl)acetic acid, vanillic acid, homovanillic acid, syringic acid, homosyringic acid, 4-hydroxybenzaldehyde, vanillin, syringaldehyde, 4-hydroxybenzyl alcohol, 2-(4-hydroxyphenyl)ethanol, vanillyl alcohol, homovanillyl alcohol, syringyl alcohol, homosyringyl alcohol, 4-hydroxyacetophenone, acetoguaiacone, acetosyringone, 4-hydroxystyrene, 3-methoxy-4-hydroxystyrene, 3,5-dimethoxy-4-hydroxystyrene, (4-hydroxyphenyl)-1-propene, (4-hydroxyphenyl)-2-propene, eugenol, iso-eugenol, syringeugenol, iso-syringeugenol, ethyl phenol, ethyl guaiacol, ethyl syringol, propyl phenol, propyl guaiacol, propyl syringol, cresol, creosol, syringyl creosol, phenol, guaiacol, syringol, benzene, toluene, xylene, ethyl benzene, propyl benzene, biphenyl, and pyrolytic oils.

52. The method of claim 1, wherein one of said components streams is cellulose, and said derivative products from cellulose comprise at least one product of aliphatic chemicals, heterocyclic chemicals, and fuels.

53. The method of claim 52, wherein said derivative products from cellulose comprise at least one product of cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and ethanol.

54. The method of claim 52, wherein said derivative products from cellulose comprise at least one product of cellulose acetate, cellulose propionate, cellulose benzoate, methyl and ethyl adipate, methyl and ethyl levulinate, methyl and ethyl succinate.
methyl and ethyl 2,5-furandicarboxylate, adipic acid, levulinic acid, succinic acid, 2,5-furandicarboxylic acid, 3,4-dehydro-.gamma.-valerolactone, .gamma.-valerolactone, 2-methyltetrahydrofuran, sorbitol, hexane-1,6-diol, pentane-1,4-diol, butane-1,4-diol, 2,5-di(hydroxymethyl)furan, 2,5-di(hydroxymethyl)tetrahydrofuran, glyercol, propylene glycol, and ethanol.

55. The method of claim 1, wherein one of said component streams is hemicellulose, and said derivative products from hemicellulose comprise at least one product of aliphatic chemicals, heterocyclic chemicals, and fuels.

56. The method of claim 55, wherein said derivative products from hemicellulose comprise at least one product of polyols, furans, dihydrofurans, tetrahydrofurans, lactones, and butenes.

57. The method of claim 55, wherein said derivative products from hemicellulose comprise at least one product of furfural, .gamma.-butyrolactone, tetrahydrofuran, ribitol, arabitol, xylitol, glyercol, propylene glycol, and isoprene.

58. The method of claim 1, wherein said plurality of derivative products comprises at least one of product of achiral, racemic, and optically pure products.

59. The method of claim 1, further comprising the step of:
using at least one of said derivative products in the production of other chemicals, materials, and products.

60. The method of claim 1, wherein said biomass has a weight, and a waste product of said biomass is less than 25% of said biomass weight.

61. The method of claim 1, wherein said biomass has a weight, and a waste product of said biomass is less than 15% of said biomass weight.

62. The method of claim 60, further comprising the step of:
producing energy utilizing said waste product.

63. A method for biorefining, comprising the steps of:
providing biomass;
processing said biomass to provide a plurality of component streams resulting in at least one waste product; and utilizing said at least one waste product to produce energy.

64. The method of claim 63, wherein said energy is heat or power.

65. A method for biorefining, comprising the steps of:
providing woody biomass, agricultural biomass, and cultivated plant biomass;
providing said woody biomass comprising at least one biomass of softwood trees, softwood shrubs, softwood bushes, hardwood trees, hardwood shrubs, hardwood bushes, hybrid trees, hybrid shrubs, hybrid bushes, cultivated trees, cultivated shrubs, cultivated bushes, forest trees, forest shrubs, forest bushes;
providing said woody biomass comprising of at least one biomass of recycled wood, recovered wood, recycled wood products, and recovered wood products;
providing said agricultural biomass comprising at least one biomass of agricultural plants, annual agricultural plants, perennial agricultural plants, biennial agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, genetically modified annual agricultural plants, native perennial agricultural plants, hybrid perennial agricultural plants, genetically modified perennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants;
providing said agricultural biomass comprising at least one agricultural residues of agricultural plants, annual agricultural plants, perennial agricultural plants, biennial agricultural plants, native annual agricultural plants, hybrid annual agricultural plants, genetically modified annual agricultural plants, native perennial agricultural plants, hybrid perennial agricultural plants, genetically modified perennial agricultural plants, native biennial agricultural plants, hybrid biennial agricultural plants, and genetically modified biennial agricultural plants;
providing said cultivated plant biomass comprising at least one biomass of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, and grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants ;
providing said cultivated plant biomass comprising at least one cultivated plant residues of cultivated plants, cultivated trees, cultivated shrubs, cultivated bushes, aquatic plants, medicinal plants, fiber plants, ornamental plants, grassy plants, annual cultivated plants, native annual cultivated plants, hybrid annual cultivated plants, genetically modified annual cultivated plants, perennial cultivated plants, native perennial cultivated plants, hybrid perennial cultivated plants, genetically modified perennial cultivated plants, biennial cultivated plants, native biennial cultivated plants, hybrid biennial cultivated plants, and genetically modified biennial cultivated plants;
processing said biomass using mechanical processing, component separation processing, optional chemical processing, residual chemical removal, and an additional treatment;
providing a plurality of component streams comprising lignin, cellulose, and hemicellulose from said biomass;
recovering chemicals used in said optional chemical processing and said residual chemical removal for recycling;
removing extractables from said optional chemical processing and said additional treatment;

reducing waste product of said biomass, wherein said biomass has a weight, and said waste product of said biomass is less than 25% of said biomass weight;
producing energy utilizing said waste product;
producing at least one product of commodity chemicals, fine chemicals, and specialty chemicals; and producing at least one product of aromatic carboxylic acids, aromatic esters, aromatic aldehydes, aryl alcohols, aryl ketones, styrenes, aryl ethanes, aryl propenes, aryl propanes, cresols, phenols, benzenes, pyrolytic oils, cellulosic esters, aliphatic carboxylic acids, aliphatic esters, polyols, ethanol, furans, dihydrofurans, tetrahydrofurans, lactones, and butenes from at least one of said component streams.