Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L97/00—Compositions of lignin-containing materials
  • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
• • A—HUMAN NECESSITIES
  • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
  • A01G—HORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
  • A01G18/00—Cultivation of mushrooms
  • A01G18/20—Culture media, e.g. compost
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
  • C08L1/02—Cellulose; Modified cellulose
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
  • D21C9/00—After-treatment of cellulose pulp, e.g. of wood pulp, or cotton linters ; Treatment of dilute or dewatered pulp or process improvement taking place after obtaining the raw cellulosic material and not provided for elsewhere
  • D21C9/001—Modification of pulp properties
  • D21C9/007—Modification of pulp properties by mechanical or physical means
• • C—CHEMISTRY; METALLURGY
  • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
  • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
  • C12P2201/00—Pretreatment of cellulosic or lignocellulosic material for subsequent enzymatic treatment or hydrolysis
• • C—CHEMISTRY; METALLURGY
  • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
  • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
  • C12P7/00—Preparation of oxygen-containing organic compounds
  • C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
  • C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
  • C12P7/06—Ethanol, i.e. non-beverage
  • C12P7/08—Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate
  • C12P7/10—Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate substrate containing cellulosic material

Definitions

• the invention relates to a process for seeding a solid lignocellulosic material with at least one filamentous fungus with a view to its development.
• the invention also relates to a process for manufacturing a solid object in which is used such a solid lignocellulosic material seeded with at least one filamentous fungus and a solid object made of composite material obtained by such a process.
• Such a process for seeding at least one filamentous fungus in a solid lignocellulosic material with a view to its development finds its applications in the field of the manufacture of solid objects in composite materials obtained essentially - in particular entirely - from natural biological resources - in particular natural plant resources - which are inexpensive and renewable. Such composite materials therefore have a low cost price, given the recovery of waste and constitute an alternative to the use of fossil resources which are not renewable.
• Such a method is of particular interest to the more general field of the recovery of plant resources, such as for example plant waste -in particular plant waste from agriculture or the food industry-, by which such vegetable waste is transformed into composite materials which are no longer waste.
• plant resources such as for example plant waste -in particular plant waste from agriculture or the food industry-, by which such vegetable waste is transformed into composite materials which are no longer waste.
• the expression “lignocellulosic material” denotes any natural material comprising at least one cellulose, at least one hemicellulose and/or at least one lignin;
• the expression “filamentous fungus” designates any multicellular eukaryotic organism, the vegetative apparatus of which is in the form of filaments or hyphae, giving the vegetative apparatus, by visual observation at the macroscopic scale, a cottony appearance;
• the term “mycelium” designates all the filaments - branched or unbranched - forming the vegetative apparatus of such filamentous fungi, and
• the term “seeding” designates the intimate mixing of the solid lignocellulosic material and the filamentous fungus(es) in contact with the lignocellulosic fibers of the solid lignocellulosic material under conditions suitable for allowing the subsequent growth of the fungus(es). s) filamentary in said composite material.
• WO2019/226823 Also known from WO2019/226823 is a process for manufacturing a product formed from a mycelial biomaterial, in which aspen shavings are mixed with an inoculum of Ganoderma lucidum so as to form a pourable composition.
• WO2019/226823 specifies that the mixing can be carried out in an auger mixer and that the chips can be subjected to a subsequent sterilization step.
• the mixture is placed in a first enclosure, then is compacted in this first enclosure in which it is subjected to aeration for a time and a temperature sufficient to allow the mycelium to develop and cover the co skins.
• the chips are removed from the first enclosure, are mixed with nutrients and then are poured into a second enclosure having the desired shape of the product formed from a mycelial biomaterial.
• the method of WO2019/226823 is complex in its implementation and requires numerous manipulations. It is in practice not industrializable.
• the method of WO2019/226823 is limited to the treatment of wood chips and does not make it possible to treat any type of lignocellulosic material, whatever its form, in particular any type of fibrous lignocellulosic material. In particular, it does not make it possible to treat any type of lignocellulosic material, such as, for example, vegetable waste from agriculture or the food industry.
• the invention aims to overcome the drawbacks mentioned above by proposing a process for seeding a solid lignocellulosic material with a fungal biomass which is capable of being implemented on an industrial scale.
• the invention aims in particular to provide such a method which is quick to implement.
• the invention relates to such a process which makes it possible to rapidly form such a solid gnocellulosic material seeded with a fungal biomass, for example in less than one hour - in particular in a period of the order of a few minutes.
• the invention relates to such a method which makes it possible to continuously form such a solid lignocellulosic material seeded with a fungal biomass.
• the invention also relates to such a method which makes it possible to continuously form such a solid gnocellulosic material seeded with at least one filamentous fungus in which the subsequent development of the filamentous fungus (s) is favored due to this process.
• the invention relates to such a method which does not require the supply of nutrients for the growth of the filamentous fungus(ies).
• the invention also relates to such a method which makes it possible to continuously form such a solid lignocellulosic material seeded with a fungal biomass, with a particle size of said solid lignocellulosic material seeded which is controlled and chosen according to the desired use. of said seeded solid lignocellulosic material.
• the invention also aims to provide such a method allowing recovery of plant resources, which are no longer waste, and which are likely to be recovered as raw material for the manufacture of objects in composite material. free of constituents of fossil origin.
• the invention aims in particular to provide such a process for treating a solid lignocellulosic material which is available in large quantities.
• Another object of the invention is to provide a process for manufacturing a composite material from such a solid lignocellulosic material seeded with a fungal biomass.
• the invention also aims to achieve these objectives at lower cost, by proposing such a process for preparing such a composite material which is simple in its implementation.
• the invention relates to a method for preparing a material, called composite material, solid lignocellulo sic seeded with at least one organism, called filamentous mushroom, multicellular eukaryote forming mycelium, in which: at least a solid lignocellulosic material impregnated with an aqueous composition is subjected to a treatment, called thermo-mechanical treatment, in which;
• said at least one impregnated solid lignocellulosic material is subjected to a succession of compression, expansion and mechanical shear phases by kneading at least one solid lignocellulosic material of said at least one impregnated lignocellulosic material, in contact with the composition aqueous tion;
• said at least one impregnated solid lignocellulosic material is brought to a temperature above 50° C.; whereby a composition, referred to as a hydrated composition, comprising a solid lignocellulosic material, referred to as hydrated lignocellulosic material, of specific surface and increased hydration rate relative to the specific surface and to the hydration rate of said at least one starting lignocellulosic material is formed as a result of this kneading and this heating, said hydrated composition being capable of being colonized by said at least one filamentous fungus, then; a composition, referred to as a fungal composition, comprising said filamentous fungus is added to said hydrated composition during mixing under mixing conditions suitable for preserving the viability of at least one such filamentous fungus and allowing further development of said fungus filamentary in said composite material; process in which the successive steps are carried out continuously in at least one twin-screw extrader between an upstream inlet of said at least
• said at least one solid lignocellulosic material impregnated is subjected to said thermo-mechanical treatment in a twin-screw extraderator and under conditions suitable for allowing defibration by at least partial disaggregation of lignocellulosic fibers solid lignocellulosic material by mechanical and thermal means and by destructuring these lignocellulosic fibers, then said fungal composition is added, comprising at least one filamentous fungus capable of developing within said at least partially disaggregated lignocellulosic material -and specific surface increased relative to the specific surface of the starting lignocellulosic material of said hydrated composition and to form a cohesive binder for the lignocellulosic fibers of said composite material due to this development -in particular by production of mycelial hyphae- .
• thermo-mechanical treatment is an at least partial sterilization treatment of the impregnated solid lignocellulosic material.
• the process according to the invention is a process for preparing said composite material in which the solid lignocellulosic material forms a support capable of allowing the development of said filamentous fungus in said composite material.
• twin-screw extruder makes it possible, using a valve, to introduce said fungal composition into the internal volume of the twin-screw extruder formed in the barrel by the screws of the twin-screw extruder, a gradual and perfectly controlled addition-in particular at a constant or variable rate-of said fungal composition into said hydrated composition during conveying in the twin-screw extruder.
• a progressive and controlled addition allows a supply of a volume, itself controlled, of said fungal composition into a small volume of said hydrated composition during conveying and mixing, flowing opposite the inlet channel of said fungal composition in the internal volume of the twin-screw extruder.
• the ratio of the volume of said hydrated composition receiving said fungal composition to the volume of said fungal composition provided to the corresponding volume of said hydrated composition is low and in any case lower than the ratio of the total volume of a composition hydrated prepared in a reactor receiving said fungal composition on the volume of said fungal composition supplied in the corresponding total volume of this hydrated composition.
• the mixing of said fungal composition in said hydrated composition is carried out more efficiently than the mixing carried out by adding said fungal composition to the total volume of said hydrated composition, as it is carried out during a mixing " in batch” in a mixing reactor.
• the addition of said fungal composition in said hydrated composition under conditions of conveying and mixing of said hydrated composition in the twin-screw extruder allows: optimal dispersion of said fungal composition in said hydrated composition and a distribution of the filamentous fungus(ies) of said fungal composition in contact with the at least partially disaggregated lignocellulosic fibers of said hydrated composition, and; an intimate mixture of said fungal composition and the at least partially disaggregated lignocellulosic fibers of said hydrated composition; while preserving—at least in part—the viability of the filamentous fungus(es) of said fungal composition during this intimate mixing.
• the subsequent development of the filamentous fungus(ies) within said composite material is favored.
• the solid lignocellulosic material of said impregnated solid lignocellulosic material undergoes at least partial destructuring by mixing and/or grinding and/or shearing and/or compression and/or relaxation of said solid lignocellulosic material combined with a heat treatment at a temperature above 50°C leading to a reduction in cohesion and dissociation at less partial lignocellulosic fibers constituting the solid lignocellulosic material.
• a thermo-mechanical treatment makes it possible to reduce the particle size of said solid lignocellulosic material to adapt it to the final use of said composite material formed.
• Such a reduction in particle size makes it possible to promote a more homogeneous distribution of said at least one filamentous fungus in said composite material, including for large volumes of said prepared composite material.
• the impregnation of said at least one solid lignocellulosic material with an aqueous composition prior to said thermo-mechanical treatment makes it possible to avoid uncontrolled heating of said impregnated lignocellulosic material and makes it possible to facilitate its subsequent defibration.
• Said hydrated composition is a composition which is substantially free of free water capable of flowing spontaneously from said hydrated composition.
• the water of said hydrated composition is associated with said solid lignocellulosic material of specific surface area and increased hydration rate relative to the specific surface area and to the hydration rate of said at least one starting lignocellulosic material.
• the amount of water associated with said solid lignocellulosic material of increased specific surface and increased hydration rate depends on the solid lignocellulosic material itself.
• said impregnated solid lignocellulosic material is formed so that the mass of dry matter of said impregnated solid lignocellulosic material on the mass of said impregnated solid lignocellulosic material is between 30% and 60%, in particular between 40% and 50%. %.
• the inventors have observed that the successive phases of compression, expansion and mechanical protrusion to which said solid lignocellulosic material is subjected in the twin-screw extruder during said thermo-mechanical treatment not only make it possible to form a lignocellulosic material disaggregated and hydrated, suitable for supporting the subsequent development of said filamentous fungus, but also allow at least partial inactivation of at least part of the endogenous microbial flora of said solid lignocellulosic material. This at least partial inactivation of this endogenous flora allows the subsequent development of said filamentous fungus in contact with the lignocellulosic fibers of said hydrated lignocellulosic material.
• thermo-mechanical treatment can be continuous or discontinuous.
• twin-screw extruder designates a mixing device comprising two co-penetrating screws with direct pitch or reverse pitch driven in rotation in synchronism inside a tubular sleeve having in cross section a bilobed shape.
• the sheath and the co-penetrating screws can be formed from any industrial alloy suited to the operating conditions, in particular abrasiveness and corrosion.
• Each of the co-penetrating screws can be formed from screw sections extending axially and successively on a splined axis and axially providing successive zones for treating the solid lignocellulosic material between an entry or loading zone of the extruder twin-screw and an exit or evacuation zone.
• twin-screw extruder comes from the speed of processing. Indeed, under the conditions of implementation of the method according to the invention, a few minutes to a few tens of minutes, depending on the dimensions of the twin-screw extruder, are sufficient to prepare said composite material.
• the screw profile -as defined by the sequence, the shape and the pitch of the constituent elements of the screws of the twin-screw extruder- and the speed of rotation of the screws in the barrel are chosen to obtain a mixing effect.
• twin-screw extruder has the advantage of allowing automation of all the steps and the realization of this treatment in a single operation and keep on going.
• twin-screw extruder advantageously allows precise control of a large number of operating parameters of a method according to the invention (treatment temperature, mode and force of compression, expansion and shear, processing time, etc.). Indeed, by modifying certain structural characteristics and/or certain operating characteristics of the twin-screw extruder, the operator intervenes on the parameters of the process.
• the screws can be conveying screws, mixing screws (such as the elements of my monolobe or bilobe laxage), shearing stress (such as counterthread screws).
• the screws may differ by the shape of their thread (which may for example be trapezoidal, conjugate, single or double, etc.) and by the size of their thread pitch.
• Each of these screws may also have different sections (or segments) which may possibly differ from one another, by the shape of the thread and/or by the thread pitch.
• some of these constituent sections of these screws may also correspond to monolobe or bilobe mixer elements.
• twin-screw extruder allows great freedom of adjustment of the conditions for implementing a method according to the invention, and in particular of defining optimal conditions (for example temperature, shear force, duration of treatment, liquid/solid ratio) specific to each of the starting solid lignocellulosic materials chosen.
• optimal conditions for example temperature, shear force, duration of treatment, liquid/solid ratio
• the screws of a twin-screw extruder used in the context of the invention can comprise at least two sections which differ in their screw profile.
• These structural characteristics of the screws of a twin-screw extruder are adapted to not only convey the solid lignocellulosic material of said solid lignocellulosic material impregnated longitudinally in the barrel of the twin-screw extruder, but also to forming, during this conveying, areas of compression and/or expansion and/or kneading and/or grinding and/or shearing and/or swelling by hydration of the solid lignocellulosic material of said solid lignocellulosic material impre gene and colonization of the disaggregated lignocellulosic fibers of said hydrated composition, by the filamentous fungus(ies).
• the method is implemented continuously by means of a single twin-screw extruder.
• a single twin-screw extruder makes it possible to subject said impregnated solid lignocellulosic material flowing continuously from upstream to downstream of G twin-screw extruder, to said thermo-mechanical treatment in an upstream part of G twin-screw extruder , then in a downstream part of the twin-screw extruder, to a mixture: of said hydrated composition conveyed by G twin-screw extruder and formed as a result of said thermo-mechanical treatment and substantially free of any endogenous flora of said lignocellulosic material starting solid, and; said fungal composition introduced into the twin-screw extruder through an introduction valve; under mixing conditions suitable for at least partially preserving the viability of said filamentous fungus(es).
• thermo-mechanical treatment of the method according to the invention is a treatment for inactivating at least a part of microbial flora in dogen of said at least one solid lignocellulosic material.
• the heating temperature and the heating time of said solid gnocellulose material impregnated in the twin-screw extruder are chosen so as to inactivate at least a part - in particular a major part, in particular substantially the totality of the endogenous mi crobienne flora of said solid lignocellulosic material.
• thermo-mechanical treatment is carried out and the addition of said fungal composition in said hydrated composition - and if necessary, cooling of said hydrated composition - to a temperature suitable for preserving at least in part - in particular in full - the viability of said filamentous mushroom(s) and to allow subsequent development of said filamentous mushroom(s) in said composite material- successively in the same twin-screw extruder.
• G twin-screw extruder has: an upstream zone for thermo-mechanical treatment of said impregnated solid lignocellulosic material; where appropriate, an intermediate zone for cooling said impregnated solid lignocellu losique material, and; a downstream zone for adding said fungal composition into said impregnated solid lignocellulosic material—if necessary cooled—and mixing said fungal composition into said impregnated solid lignocellulosic material.
• thermo-mechanical treatment and the addition of said fungal composition to said hydrated composition are carried out successively in different twin-screw extruders.
• the heating temperature of said at least one solid lignocellulosic material impregnated during the thermo-mechanical treatment is between 50° C. and 180° C., preferably between 130° C. and 150° C. vs.
• said hydrated composition is cooled to a temperature below 50° C., in particular between 5° C. and 50° C., prior to the addition of said fungal composition.
• the cooling of said hydrated composition is carried out continuously in G twin-screw extruder, by conveying said hydrated composition to be cooled in at least one section of G twin-screw extruder provided with a sleeve maintained at the cooling temperature.
• the cooling of said hydrated composition is carried out continuously in G twin-screw extruder, by conveying said hydrated composition to be cooled in at least one section of G twin-screw extruder provided only with conveying screws, c that is to say screws free of alternating compression and relaxation members.
• Such combined and inter-penetrating conveying screws allow said hydrated composition to be conveyed in the extruder and promote heat exchange with the sleeve maintained at the cooling temperature.
• said at least one impregnated solid lignocellulosic material comprises an amount of said at least one solid lignocellulosic material such that the ratio of the mass of dry matter of said at least one solid lignocellulosic material to the mass of said at least one impregnated solid lignocellulosic material is between 30% and 60%, in particular between 40% and 50%.
• the ratio of the mass of dry matter of said solid lignocellulosic material of the impregnated solid lignocellulosic material to the total mass of said solid lignocellulosic material impregnated is between 30% and 60%.
• said impregnated solid lignocellulosic material is formed in the twin-screw extruder by introducing a flow of aqueous composition into the flow of lignocellulosic material being conveyed in the twin-screw extruder, so as to form an impregnated solid lignocellulosic material comprising a quantity of solid lignocellulosic material such that the ratio of the mass of dry matter of said at least one solid lignocellulosic material to the mass of said solid lignocellulosic material impregnated is between 30% and 60%, in particular between 40% and 50%.
• the mass of such dry matter is determined by a method known per se to those skilled in the art and by which said matter is weighed beforehand exposed to drying at a temperature of the order of 103 ° C for a time necessary to obtain a substantially constant mass, this substantially constant mass being representative of the mass of the dry matter of said solid lignocellulosic material.
• the quantity of aqueous composition in said at least one impregnated solid lignocellulosic material -in particular the quantity of water in said at least one impregnated solid lignocellulosic material- is adjusted so that said composite material is free of free aqueous composition capable of flowing spontaneously from said composite material.
• the quantity of aqueous composition -in particular the quantity of water- in said at least one impregnated solid lignocellulosic material is adjusted so that said composite material has an optimized humidity level to allow optimal growth of the Filamentous fungus(es).
• said composite material comprises a quantity of said hydrated lignocellulosic material (of specific surface and increased hydration rate compared to the specific surface and to the hydration rate of said at least one starting lignocellulosic material ), such that the ratio of the mass of dry matter of said hydrated lignocellulosic material to the mass of said composite material is between 10% and 30%—in particular between 15% and 30%—.
• said hydrated lignocellulosic material has a particle size smaller than that of said at least one starting solid lignocellulosic material and smaller than that of said at least one impregnated solid lignocellulosic material.
• This particle size may vary according to the choice of the starting solid lignocellulosic material and according to the conditions of implementation of said thermomechanical treatment, in particular according to the profile of the twin-screw extruder.
• the lignocellulosic fibers of said hydrated composition have a greater dimension (in particular a length) on average between 10 3 m and 10 2 m and a smallest dimension (in particular a diameter) orthogonal to the largest dimension less than 2 10 3 m.
• filamentous fungus can be used provided it is of the mycelium-producing type.
• said filamentous fungus is chosen from the group formed by organisms of the Basidiomycota phylum.
• said filamentous fungus is chosen from the group made up of Grammothele fuligo, Pleurotus citrinopileatus (yellow oyster mushroom), Lentinula edodes (or oak or shiitake or shiitake duckweed), Pleurotus ostreatus (oyster-shaped pleurotus or gray oyster mushroom), Pleurotus pulmonarius (pulmonary oyster mushroom ), of Pleurotus columbinus, of oyster mushroom hybrids, of Ganoderma resinaceum (Ganoderma resinous), of Agrocybe brasiliensis, of Flammulina velutipes, of Hypholoma capnoides, of Hypholoma sublaterium, of Morchella angusticeps,
• Such filamentous fungi developing in contact with the disaggregated lignocellulosic fibers in said composite material produce biological material forming a cohesive binder in said composite material by filling spaces left vacant by the lignocellulosic fibers.
• biological material may comprise structural proteins constituting the mycelium of the filamentous fungus(ies), and/or excreted proteins and/or chitin.
• said at least one impregnated solid lignocellulosic material is prepared prior to its introduction into the twin-screw extruder, by adding the aqueous composition to said at least one solid lignocellulosic material.
• said at least one solid lignocellulosic material comprises: a mass proportion of celluloses, expressed in dry weight of celluloses and in dry weight of said at least one solid lignocellulosic material (that is to say by the ratio of the mass of dry matter of cellulose to the mass of dry matter of said at least one dry lignocellulosic matter) of between 20% and 99%, in particular between 20% and 98%, in particular between 20% and 90%, preferably between 30% and 60%; a mass proportion of hemicelluloses, expressed in dry weight of hemicelluloses and in dry weight of said at least one solid lignocellulosic material (that is to say by the ratio of the mass of dry matter of the hemicelluloses to the mass of material dry matter of said at least one solid lignocellulosic material) comprised between 10% and 50%, in particular comprised between 10% and 35%; a mass proportion of lignins, expressed in dry weight of lignins and in dry weight of said at
• Any solid lignocellulosic material can be used in a process according to the invention, including cotton.
• At least one solid lignocellulosic material is chosen from the group consisting of all or part of a herbaceous plant -in particular a cereal (such as, for example, wheat, barley, rice, oats, in particular), cereal straw, stems of a cultivated plant (such as sorghum, corn, sugar cane, etc.) -, all or part of a ligneous plant (bark, wood shavings), waste from a plant resulting from the recovery of the said plant (chives, cake from a plant oilseed, in particular) and all or part of a plant producing vegetable fibers such as sisal, flax, coconut, hemp, jute, ramie, cotton, or tie nettle, for example.
• a cereal such as, for example, wheat, barley, rice, oats, in particular
• cereal straw such as, for example, wheat, barley, rice, oats, in particular
• stems of a cultivated plant such as sorghum, corn, sugar cane,
• said fungal composition is added to said hydrated composition maintained at a temperature between 10°C and 30°C, in particular between 20°C and 30°C.
• said hydrated composition is cooled during its conveyance in the twin-screw extruder so as to reach this temperature of between 10°C and 30°C.
• the temperature of said hydrated composition is adjusted by cooling at least one longitudinal section of the barrel of the twin-screw extruder.
• thermo-mechanical treatment is carried out continuously in at least one twin-screw extruder comprising, from upstream to downstream, a succession of sections of rotary screws combined with a tubular sleeve of G bi-extruder -screw, adapted so that said at least one impregnated solid lignocellulosic material is subjected, during its conveying from upstream to downstream in the twin-screw extruder, to increasing compressive, shear and expansion stresses.
• the succession of sections of rotary screws combined with the tubular sheath of G twin-screw extruder comprises at least one conveying screw and at least one constraining screw - such as screws of the bilobe mixer type mounted at 90° or - 45°, or of the perforated counterthread type or screws with a pitch wider than the conveying screws placed upstream.
• said thermo-mechanical treatment is carried out continuously in at least one twin-screw extruder having, from upstream to downstream, in this order: at least one section provided with a chosen conveying screw in the group formed by C1F type single-threaded mating screws, C2F type double-threaded mating screws, T2F type double-threaded trapezoidal screws, T1F-type single-threaded trapezoidal screws and their variants, then; at least one section provided with a constraint screw chosen from the group formed by monolobe screws mounted at +45°, bilobe screws mounted at +45° (corresponding to an angle offset of +45° between the elements to the others), monolobe screws mounted at +90°, bilobe screws mounted at +90° (corresponding to an angle offset of +90° of the elements relative to each other), monolobe screws mounted at -45°, bilobe screws mounted at -45° (corresponding to an angle offset of -45° of the elements relative to each other) and inverted screws, called "counterth
• said fungal composition is a liquid composition.
• said liquid fungal composition is added to said hydrated composition so that said composite material has a humidity level optimized and adapted to allow optimal growth of the said filamentous fungus(ies).
• said liquid fungal composition is added to said hydrated composition so that said composite material comprises a quantity of said hydrated lignocellulosic material (of specific surface and increased hydration rate compared to the specific surface and to the rate of hydration of said at least one starting lignocellulosic material) such that the ratio of the mass of dry matter of said hydrated lignocellulosic material to the mass of said composite material is between 10% and 30% -in particular between 15% and 30%- .
• the mixing of said liquid fungal composition and of said hydrated composition is carried out in at least one section of twin-screw extruder equipped with screws of a type of conjugated and inter-penetrating conveying screws.
• Such a type of conveying screw allows effective mixing and effective impregnation of said fungal composition in said hydrated lignocellulosic material to form said composite material
• said fungal composition is a solid composition.
• the mixing of said solid fungal composition and of said kneaded dispersion is carried out in at least one section of twin-screw extruder equipped with conveying screws chosen from the group formed by conjugate screws with single thread of the GIF type , C2F-type double-threaded mating screws, T2F-type double-threaded trapezoidal screws, T1F-type single-threaded trapezoidal screws and their variants, and/or; constraining screws of the monolobed mixer type or of the bilobed mixer type (BB +45° or MAF0 +45°), whose monolobes or bilobes respectively are oriented perpendicular to the splined shafts and are offset from each other by an angle of +45°, and/or; constraining screws of the monolobed mixer type or of the bilobed mixer type (BB 90° or MAF090°), whose monolobes or
• the invention extends to a composite material obtained by a process according to the invention.
• the invention also extends to a solid lignocellulosic material, called composite material, comprising lignocellulosic fibers and at least one organism, called filamentous fungus, multicellular eukaryote that forms mycelium, said composite material being mainly in the form of particles of generally elongated shape and having a greatest dimension (a length) greater than each of the two dimensions (width and thickness) orthogonal to the greatest dimension and orthogonal to each other, the ratio of the greatest dimension (length) to each dimensions orthogonal to the largest dimension (width and/or thickness) being greater than 2, in particular greater than 4, preferably greater than 6, even more preferably greater than 10.
• the invention also extends to any use of such a composite material obtained by a preparation process according to the invention.
• the invention relates in particular to the use of said composite material -obtained or not by a process for the preparation according to the invention- for the purposes of at least partial -notably total- digestion of a solid lignocellulosic material capable of being decomposed by said developing filamentous fungus(es) - in particular prior to a step of enzymatic hydrolysis of the cellulose of the decomposed solid lignocellulosic material and its conversion into fermentable sugars for the production of ethanol.
• the invention therefore relates to a method according to the invention for the preparation of a composite material for the purposes of at least partial—in particular total—digestion of said solid lignocellulosic material.
• the invention also extends to a method for manufacturing a solid object in which is implemented a method according to the invention for preparing said composite material.
• the invention also extends to such a process for manufacturing a solid object in which a composite material obtained by a process according to the invention is chosen, then said composite material is shaped and said composite material is subjected to thus shaped, at a stage of fermentation, called fermentation in a solid medium, and of development of said at least one filamentous fungus in said composite material.
• Said fermentation in a solid medium can be an anaerobic or aerobic fermentation.
• the fermentation in a solid medium and the development of the filamentous fungus(ies) occur in contact with the hydrated lignocellulosic material of the said composite material in the quasi-total absence of free water, the said hydrated lignocellulosic material acting as a support for this fermentation and this development, but also, where appropriate, as a nutrient source for the filamentous fungus(ies).
• the solid object manufactured being a molded object of low density: said composite material is shaped -in particular by molding- obtained by a process for preparing said composite material according to the invention, then; said shaped composite material is subjected to a step of fermentation, called fermentation in a solid medium, and of development of said at least one lying fila fungus in said composite material, whereby a material enriched in mycelium is formed, then; the material enriched in mycelium is dried so as to form the molded solid object consisting of a composite material of low density.
• the composite material of low density may have a density of less than 0.1 g/cm 3 .
• the solid object manufactured being an object of density greater than 0.1 g/cm 3 , in particular of mass volume between 0.6 g/cm 3 and 1.4 g/cm 3 , in particular between 0.6 g/cm 3 and 1.0 g/cm 3 - and greater than the density of the material enriched in mycelium forming a solid object obtained by simple molding: said composite material is subjected to a stage of fermentation, called fermentation in a solid medium, and development of said at least one filamentous fungus in said composite material and in contact with said hydrated lignocellulosic material, this whereby a mycelium-enriched material is formed, then; said material rich in mycelium is subjected to a shaping step by thermo compression, if necessary after drying and/or grinding of said material enriched in mycelium, so as to form the solid object of density greater than 0.1 g/cm 3 .
• the material forming the solid object has a density greater than 0.1 g/cm 3 , in particular between 0.6 g/cm 3 and 1.4 g/cm 3 , in particular between 0.6 g/cm 3 and 1.0 g/cm 3 .
• the manufacturing process does not include any addition in said composite material of a nutrient composition for aiding the development of said at least one filamentous fungus.
• a nutrient composition for aiding the development of said at least one filamentous fungus.
• the invention also relates to a method for preparing a material, called composite material, solid lignocellulo sic seeded with at least one filamentous fungus and a method for manufacturing a solid object characterized in combination by all or part of the characteristics mentioned above or below.
• a material called composite material, solid lignocellulo sic seeded with at least one filamentous fungus
• a method for manufacturing a solid object characterized in combination by all or part of the characteristics mentioned above or below.
• Figure 1 is a block diagram of a variant of a method according to the invention.
• FIG 2 is a block diagram of an example of a twin-screw extruder capable of being used for the implementation of a first variant of a method according to the invention, and;
• FIG 3 is a functional diagram of an example of a twin-screw extruder capable of being used for the implementation of a second variant of a method according to the invention.
• a solid lignocellulosic material 4 composed of celluloses, hemicelluloses and lignin is chosen.
• a solid lignocellulosic material 4 can be a vegetable material resulting from agriculture or forestry or growing in the wild state. It can be all or part of an agricultural production. It may in particular be a part of such agricultural production, considered as waste vis-à-vis this agricultural production and which, because of its use in a method according to the invention, constitutes an enhancement of this agricultural production.
• the solid lignocellulosic material 4 is formed from a plant resource which is renewable.
• a substantially continuous introduction 17 of a flow of fragmented solid lignocellulosic material 4 is carried out in the upstream part of a twin-screw extruder 10 configured to be able to receive the material. 4 solid lignocellulosic material and for conveying this solid lignocellulosic material 4 between the upstream inlet of the lignocellulosic material 4 in G twin-screw extruder 10 and a downstream outlet of said composite material 1 formed in the extruder 10.
• a flow of an aqueous composition 5 -in particular water- is added 19 to the barrel of the extruder 10 so as to form a solid lignocellulosic material 3 impregnated with aqueous composition 5 due to the conveying of the solid lignocellulosic material 4 and its kneading.
• the flow rate of aqueous composition 5 is adjusted according to the nature and composition of the solid lignocellulosic material 4, so that the ratio of the mass of dry matter to the solid lignocellulosic material 4 in said impregnated lignocellulosic material 3 is between 40% and 60%.
• thermo-mechanical treatment 6 by which said impregnated lignocellulosic material 3 is subjected to a succession of compression phases, expansion and mechanical shearing by kneading said at least one solid lignocellulosic material 4 in contact with the aqueous composition 5 and heating to a temperature above 50°C, in particular between 50°C and 180°C.
• thermo-mechanical treatment 6 there is nothing to prevent said thermo-mechanical treatment 6 from being carried out at a temperature above 180°C, but without the risk of burning the lignocellulosic material 4.
• thermo-mechanical treatment 6 of said impregnated lignocellulosic material 3 is carried out by heating the sleeve(s) of the module(s) of the extruder 10 corresponding to the heating zone.
• a hydrated composition 7 comprising a hydrated lignocellulosic material 8, of specific surface area and increased hydration rate relative to the specific surface area and to the hydration rate of the lignocellulosic material 4 introduced into G extruder 10.
• thermo-mechanical treatment 6 The conditions of said thermo-mechanical treatment 6 are chosen, in particular compression / expansion and heating so as to form a hydrated composition 7 substantially free of endogenous microbial flora of the starting material 4 solid lignocellulosic. According to the invention, said thermo-mechanical treatment 6 makes it possible to form said hydrated composition 7 in which said hydrated lignocellulosic material 8 is adapted to be able to be subsequently colonized by a filamentous fungus 2.
• said hydrated composition 7 is subjected to cooling 18 by continuing to convey said composition 7 hydrated through successive sleeves of modules, called cooling modules, of the extruder 10 brought to low temperature, in particular at a temperature between 10° C. and 30° C., corresponding to a zone of the extruder 10 for cooling said composition 7 hot hydrated.
• cooling modules modules
• composition 9 fungal comprising at least one filamentous fungus 2.
• said fungal composition 9 is added to said cooled hydrated composition 22 during mixing, under mixing conditions suitable for preserving, at least partially, the viability of the fungus(ies) 2 filament you.
• a material, called composite material 1 is thus formed, formed of a solid lignocellulosic material seeded with viable filamentous fungi 2, substantially uniformly distributed in the solid lignocellulosic material and capable of developing mycelium in contact with the solid lignocellulosic material and the colonize.
• the mixing is maintained by conveying said composite material 1 in the extruder 10 so as to promote a redistribution of the filamentous mushrooms 2 in contact with the lignocellulosic fibers of the lignocellulosic material. Said composite material 1 is expelled continuously from the extruder 10 at its downstream longitudinal end.
• said composite material 1 is subjected to a treatment 23 for shaping said composite material 1. It can be a spreading of said composite material 1 on a support of predetermined shape or any other type of shaping.
• the shaped composite material is then placed under conditions suitable for allowing the development, by fermentation 12 on a solid medium, of the filamentous fungus(ies) 2 in contact with the lignocellulosic fibers. The development of the mycelium of the mushroom(s)
• said composite material 1 is placed under conditions suitable for allowing the development of the filamentous mushroom(s) 2 in contact with the lignocellulo fibers. siques, by fermentation 12 on solid medium.
• the development of the mycelium of the filamentous fungus(ies) 2 in contact with the lignocellulosic fibers makes it possible to form a fungal binder ensuring the cohesion of a material 13 enriched in mycelium.
• the material 13 enriched in mycelium is then shaped by thermocompression, whereby a solid object 15 with a density greater than 0.1 g/cm 3 is formed.
• the material 13 enriched in mycelium is subjected to a compression stage under a pressure of 785 Kg/cm 2 so as to form a standardized specimen.
• the standardized test piece has a flexural strength value of the order of 19 MPa and a flexural modulus of elasticity of the order of 2200 MPa.
• a standardized specimen obtained by compression of a solid lignocellulosic material which has undergone said thermo-mechanical treatment but which is not enriched in mycelium and subjected to the same compression step under 785 Kg/cm 2 has a flexural strength value of the order of 7 MPa and a flexural modulus of elasticity of the order of 370 MPa.
• This compressed material not enriched in mycelium is a friable material, unlike the material forming the solid object according to the invention.
• the development of the mycelium of the filamentous fungus(ies) 2 in contact with the lignocellulosic fibers is made possible due to the thermo-mechanical treatment 6 of the material 3 solid lignocellulosic material and its sterilization, at least partially, due to this treatment 6 in the extruder 10.
• the inventors have observed that a solid lignocellulosic material which has not undergone said thermo-mechanical treatment 6 at least partially sterilizing does not allow the development of the mycelium of the filamentous fungus(ies). They assume that the development of the natural flora of such a solid lignocellulosic material opposes the development of the filamentous fungus(ies).
• EXAMPLE 1 Sowing Chènevotte with a liquid suspension of the filamentous fungus Grammothele fuligo
• a hemp shiv composed of 44% celluloses, 18% hemicelluloses and 28% lignin, formed of fragments of generally cylindrical shape and of average cross-sectional diameter included between 0.5mm and 6.3mm.
• 70% of the fibers of the hemp hemp having a diameter greater than 2 mm.
• the hemp hemp in equilibrium in the ambient atmospheric air has a rate (ratio of the constant mass of the hemp hemp maintained at the temperature of 103° C. to the mass of the balanced hemp hemp in ambient atmospheric air at room temperature) dry matter of 87%.
• a CLEXTRAL EV25 twin-screw extruder (CLEXTRAL SA, Firminy, France) is chosen comprising a fixed and hollow sleeve forming a longitudinal bore of bilobed shape in transverse cross section, and two identical parallel shafts each driven in rotation in one of the lobes of the bilobed sleeve along the longitudinal axis of each of the two shafts and at an identical speed of rotation and in the same direction of rotation.
• the sheath is made up of 10 successive bilobed modules of the same size (each 100 mm long) mounted linearly integral with each other.
• Each rotary shaft is equipped longitudinally with a succession of screw sections mounted integral in rotation with the shafts.
• Each screw has a maximum cross-sectional diameter of 25 mm, the screws mounted opposite on each of the two shafts being of the same length and of the co-penetrating type.
• These co-penetrating screws are sized and adapted to cooperate with the bilobed bore of the sheath to subject the hemp hemp to a con trip in a generally longitudinal direction with respect to the sheath and to a mechanical work of shearing and mixing with the means of successive sequences of compression, shearing and relaxation of the material in the barrel of the extruder.
• the speed of rotation of each shaft and each screw is 200 revolutions per minute (rpm).
• the particular configuration of the CLEXTRAL EV25 twin-screw extruder is described by way of example in figure 2.
• the sleeve of the extruder is shown schematically in Figure 2 extends over a total length of 1000 mm.
• M designates the modules (M1 to M10)
• t designates the regulation temperature of the corresponding module
• NV represents the number of unit screw sections
• TV represents the type of screw
• P/A represents the pitch of the screw or alternatively the angle of the lobes
• L represents the length of each screw unit section.
• the extruder is made up of a succession of 10 modules (M1 to M10) of the same length, linearly linked together.
• the sleeve of the M1 module is open so as to allow introduction of the solid lignocellulosic material into the twin-screw extruder.
• the sheath of module M2 has a side orifice for introducing said aqueous composition into the sheath of the extruder and into contact with the lignocellulosic material being conveyed.
• said aqueous composition is water introduced into the barrel of the extruder by means of a pump with a flow rate of the order of 1.2 kg/h.
• the open sheath of the M6 module is adapted to allow evacuation of the water vapor produced upstream due to said thermo-mechanical treatment.
• the sheath of the M8 module has an orifice communicating with a side member for introducing said fungal composition into said hydrated composition during conveyance in the twin-screw extruder, the introduction member comprising a piston pump (Milroyal ® Dosapro, Milton Roy) delivering a flow rate of said fungal composition of 1.6 kg/h.
• the twin-screw extruder is equipped, as described in Figure 2: with conveyor screw sections, denoted C2L, conjugate and with double thread having a screw pitch with a length of 1.25D or 1D or 0 .75D or 0.5D, representing the length of each screw section.
• the constant "D" is equal to 25 mm.
• Such conveying screws of the C2L type allow conveying of the lignocellulosic material longitudinally in the sheath, while allowing mixing of the lignocellulosic material due to the co-penetrating profile of the screws; sections of trapezoidal screws, denoted Tl F, with single thread and having a screw pitch with a length of 0.75D and adapted to allow the introduction of the lignocellulosic material into the barrel of the twin-screw extruder and its conveyance; bilobed mixing discs, denoted BB 90°, whose bilobes are oriented perpendicularly to the splined shafts and are offset from each other by an angle of 90°.
• Such mixing disks are suitable for allowing the application of moderate mechanical stresses on the lignocellulosic material and effective mixing of the lignocellulosic fibers in the aqueous composition. Such mixing discs also make it possible to produce moderate shear forces on the solid fragments.
• the fungal composition is formed from a mycelial suspension in sterile water, of the filamentous fungus Grammothele fuligo previously cultured in a bioreactor.
• the fungal composition has a proportion of dry matter of 7.5 g/L of mycelial suspension.
• the modules 6 to 10 of the extruder Prior to the introduction of the chènevotte into the twin-screw extruder, the modules 6 to 10 of the extruder are subjected to a treatment by a steam jet intended to limit the risks of contamination by the extruder itself.
• the pump of the member introducing said fungal composition into said hydrated composition is treated with an aqueous mixture of ethanol at 70°.
• the chènevotte is introduced into the extruder with an introduction rate of 1 kg/h corresponding to an introduction rate expressed in mass of dry matter of the chènevotte of 0.87 kg/h.
• the process for preparing said composite material makes it possible, by shaping said composite material in a mould, followed by a step of fermentation on a solid support for 7 to 15 days of said composite material at a temperature of 25° C. and production of a material enriched in mycelium, the production of a solid object formed of a molded material of low density, in particular of density of the order of 0.09 g/cm 3 .
• the process for preparing said composite material also allows, after drying and if necessary grinding of the material enriched in mycelium, the manufacture of heat-pressed materials of increased mechanical strength by the supply of proteins and chitin resulting from the development of the filamentous fungus.
• the invention is not limited to the use of chènevotte and the density of the solid object formed from a molded material can vary according to the density of the starting solid lignocellulosic material chosen. and depending on the shaping conditions.
• Such a heat-pressed material may have a flexural strength value of between 8 MPa and 40 MPa, in particular of between 9 MPa and 20 MPa and a flexural modulus of elasticity of between 800 MPa and 6000 MPa, in particular of between 800 MPa and 2300 MPa.
• EXAMPLE 2 Seeding of shiv with a solid composition of the filamentous fungus Lentinula edodes
• the sheath of the extruder represented schematically in FIG. 3 extends over a total length of 1000 mm. It is made up of a succession of 10 modules (M1 to M10) of the same length, linearly connected to each other.
• the sheath of the module M1 is open so as to allow introduction of the solid lignocellulosic material into the twin-screw extruder.
• the sheath of the module M2 has a side orifice for introducing said aqueous composition into the sheath of the extruder and in contact with the lignocellulosic material being conveyed.
• said aqueous composition is water introduced into the barrel of the extruder by means of a pump with a flow rate of the order of 1.1 kg/h.
• the sheath of the M6 module has a side orifice for introducing water into the sheath of the extruder.
• a second injection of water is carried out in the sheath at the level of the module M6, by means of a pump with a flow rate of the order of 1.95 kg/h.
• This water supply makes it possible to control the water content of said composite material coming out of the extruder and allowing the subsequent development of the filamentous mushroom(s).
• the sheath of the M8 module has an orifice communicating with a side member for introducing said fungal composition into said hydrated composition during conveyance in the twin-screw extruder, the introduction member comprising a piston pump delivering a flow rate of said fungal composition of 1.6 kg/h.
• the twin-screw extruder is provided, as described in Figure 3: with conveyor screw sections, denoted C2F, conjugate and with double thread having a screw pitch with a length of 1.25D or 1D or 0 .75D or 0.5D, the constant “D” representing the length of each screw section.
• the constant “D” is equal to 25 mm.
• Such conveyor screws of the C2F type allow the lignocellulosic material to travel longitudinally in the sheath, while allowing mixing of the lignocellulosic material due to the co-penetrating profile of the screws; trapezoidal screw sections, denoted Tl F, with single thread and having a screw pitch with a length of 0.75D and adapted to allow the introduction of the lignocellulosic material into the barrel of the twin-screw extruder and its conveyance; bilobed mixing discs, denoted BB 90°, whose bilobes are oriented perpendicularly to the splined shafts and are offset from each other by an angle of 90°.
• Such mixing discs are suitable for allowing the application of moderate mechanical stresses on the lignocellulosic material and effective mixing of the lignocellulosic fibers in the aqueous composition.
• Such mixer discs also make it possible to produce moderate shearing forces on the solid fragments; bilobed mixing discs, denoted BB +45°, whose bilobes are oriented perpendicularly to the splined shafts and are offset from each other by an angle of +45°.
• Such mixing discs are adapted to allow the application of less intense mechanical stresses than 90° BBs.
• Such mixing discs are chosen to allow effective mixing of the lignocellulosic fibers in the aqueous composition while ensuring their conveyance.
• the process for preparing said composite material makes it possible, by shaping said composite material in a mould, followed by a step of fermentation on a solid support for 7 to 15 days of said composite material at a temperature of 25°C and producing a mycelium-enriched material, producing a solid object formed from a low density molded material.
• the invention may be the subject of numerous variants and applications other than those described above.
• the various structural and functional characteristics of each of the embodiments described above should not be considered as combined and/or closely and/or inextricably linked to each other, but on the contrary as mere juxtapositions.
• the structural and/or functional characteristics of the various embodiments described above may be the subject, in whole or in part, of any different juxtaposition or any different combination.

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• 2021
  • 2021-03-16 FR FR2102617A patent/FR3120867B1/fr active Active
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