JP2012507276A - Biomass processing process and system - Google Patents

Abstract

The present invention provides methods (processes) and systems for processing biomass, for example creating biofuels, such as bioethanol, from biomass. Even more particularly, a method according to the present invention includes (a) inducing at least a first portion of a composition containing biomass and working fluid to flow into a passage of a fluid treatment device, (b) fluid treatment. A high velocity transport fluid is injected into the composition through a nozzle that communicates with the passage of the device, whereby the transport fluid is subdivided into working fluid and a vapor and droplet flow pattern is formed downstream of the nozzle. Applying a shear force to the composition, (c) condensing vapor and droplet flow patterns, (d) transferring the composition to a first holding vessel, and (e) applying the composition to the first Holding in a holding container at a first predetermined temperature for a first predetermined time, wherein liquefying enzyme is added to the composition before or during the process. Thereafter, the composition can be further processed to form a biofuel, such as bioethanol.

Description

  Cross-reference of related applications. This application claims priority to US patent application Ser. No. 12 / 290,700, filed on Oct. 30, 2008, which includes international applications PCT / GB2008 / 050210 and 2008, filed Mar. 21, 2008. Profit under 35U.SC §120 of international application PCT / GB2008 / 050319 filed May 2, The contents of all applications identified above are hereby incorporated by reference as if fully set forth herein.

  Field of the invention. The present invention provides, inter alia, biomass (biomass) treatment processes and systems that are suitable for use in the production of biofuels, including bioethanol. Even more particularly, the present invention provides a single process and system for the conversion of both starch (starch) and cellulose present in a biomass composition to alcohol.

  The conversion of biomass to biofuels has become of great importance in recent years as consumers and producers are similarly aware of the environmental and sustainability issues surrounding existing fossil fuels. The majority of existing biofuels are derived from fermentation of sugar crops and crops with high starch content, which is referred to below as the “first generation” process. First generation processes typically require an initial hydration step in which the underlying starch-based raw material is mixed with water to form a slurry. The water can be preheated prior to mixing with the raw materials. The slurry can additionally be heated in a container to activate the starch and then heated again and mixed with the liquefaction enzyme to convert the starch into long-chain sugars (sugar). The activation stage typically uses steam-jacketed tanks or steam sparger heating to heat the slurry to the desired temperature. At the same time, a stirring mixer, a slurry recirculation loop, or a combination of the two mixes the slurry. However, despite the presence of a recirculation pump, these heating methods can result in an area in the slurry tank or vessel where the temperature is created significantly higher than the rest of the tank. In such a process, the starch that hydrates early in the process is compromised if it comes in contact with these high temperature regions, examples can be modified and lower yields are reduced. Bring rate. Also, these arrangements do not provide particularly effective mixing, as evidenced by the thermal damage problem described above and also the poor hydration of the starch.

  These first generation processes typically use separate vessels for process activation and transformation stages. The movement of the slurry from the activation vessel to the conversion stage vessel is usually accomplished using a centrifugal pump, which provides a high shear force on the slurry and consequently hydrates. Causes further damage to starch.

  The conversion stage can also be used with a steam- or water-jacketed tank, or a tank heated by a sparger heater, to raise the temperature of the slurry to an appropriate level for optimal performance of the liquefaction enzyme. Alternatively, a jet cooker (cooking utensil) is used to heat the mud coming into the conversion stage container. Not only can the slurry suffer the same thermal damage as in the activation stage, but the high temperature region also contributes to limiting the glucose yield from the process. Excessive heat in these areas promotes Maillard reactions, where sugar molecules are destroyed due to interactions with proteins also present in the slurry. The combination of shear damage from the transfer pump and these Maillard losses limits the available glucose yield. Moreover, existing liquefaction processes require a long residence time for the slurry to ensure that as much starch as possible is converted to sugar during the conversion stage. This has a negative impact on time and manufacturing process costs.

  Crops with high starch content have high value in food applications (both human and animal feed) and only a small percentage of total crops when compared to the potential sugar yield from cellulose and hemicellulose Due to the starch, their sugar yield per hectare is low. Thus, the process for derivation of biofuels from alternative sources of biomass, such as lignocellulosic biomass consisting primarily of lignin, hemicellulose and cellulose, is lignocellulosic biomass with very large amounts of biomass. So it is very important for producers. This includes, for example, all trees and grasses, and agricultural residues, such as wet and dry distiller's grains, corn fiber, corn cobs and sugarcane bagasse .

  The process of deriving biofuel from lignocellulosic biomass is hereinafter referred to as the “second generation” process. The second generation process consists of three stages: a first pretreatment stage that destroys the cellular cellular structure of the biomass, and a second hydrolysis stage where the cellulose portion of the biomass is converted to short chain sugars. , And in a third fermentation stage where these sugars are converted to alcohol, lignocellulosic biomass is converted to alcohol (eg, ethanol).

  In order to increase the yield of hydrolysis, a pre-treatment step is necessary to soften the biomass and destroy its cellular structure, thereby exposing more cellulose and hemicellulose materials. Destructive pretreatment processes are usually chemical or physical in nature. The current chemical pretreatment process relies on a catalyst to achieve the desired destruction of biomass cells. This catalyst is usually an acid or an enzyme. Enzymes are relatively expensive, but acids have the disadvantage of being harmful to the environment. The most common physical pretreatment process is a steam explosion, examples of which include Neves, US Pat. No. 4,425,433, issued January 10, 1984, and Hoody. Of U.S. Pat. No. 4,461,648 issued July 24, 1984. In a steam explosion, the biomass is heated with high pressure steam for several minutes (a few minutes) before the reaction is stopped by a sudden depressurization to atmospheric pressure. The disadvantage of steam explosion is that the process must be contained within a suitable process vessel and is thus a discontinuous process. Furthermore, while the current cost for the process is high, the sugar yield from the steam explosion is relatively low.

U.S. Pat.No. 4,425,433 U.S. Pat.No. 4,461,648

  In both the first and second generation processes, yeast is used to ferment sugar. However, yeast is temperature sensitive and the biomass must be cooled to approximately 30 ° C. before the yeast can ferment sugar. If the fermented biomass must be reheated downstream for distillation, cooling the biomass not only increases the length of the fermentation process, but also increases energy consumption.

  The first generation process described above is most commonly used in the current biofuel industry. In order to reduce the cost of transporting crops for processing, biofuel processing plants typically create a local market for two products (eg, ethanol and animal feed) from the area where the crop grows or from the process. It is positioned in close proximity to the area it has. Still further, in an effort to reduce costs, starch-based components of crops (eg, corn kernels) are separated from the rest of the crop (eg, stalks and leaves) during harvesting, resulting in starch-based components. Only the ingredients are transported to the processing plant. However, despite this separation during harvesting, approximately 10% by weight of the crops transported for processing are from lignocellulosic materials (eg corn hulls, corn cobs) that are free of starch. Composed. Thus, even if 10% of the crop is transported to the processing plant in the first generation process, there is a negligible yield from that transported 10%.

  The solution to this problem is also to use a second generation process to obtain the alcohol from the lignocellulose material. However, operating both the first and second generation processes next to each other in a single processing plant has a significant impact on processing costs. First of all, the establishment cost related to building a processing facility with separate processing lines for the first and second generation processes is to build a factory with only the first generation process lines Much larger than the ones. Secondly, the production costs of driving the various stages of the two processes beside each other are also greater than those associated with driving only the first generation process lines.

  Accordingly, one object of the present invention is to overcome one or more of the aforementioned disadvantages.

Summary of the invention. According to a first aspect of the present invention, a method for the treatment of biomass is provided, which comprises (i) a composition comprising biomass and a working fluid so as to flow into the passage of a fluid treatment device Inducing things,
(Ii) injecting a high velocity transport fluid into the composition through a nozzle communicating with the passage of the fluid treatment device, whereby the transport fluid is subdivided (atomized) into the working fluid and the flow of vapor and droplets Applying a shear force to the composition such that a droplet flow regime is formed downstream of the nozzle;
(Iii) condensing the vapor and droplet flow patterns, and transferring the composition to a first holding vessel; and (iv) a first predetermined (predetermined) in the first holding vessel. ) Holding the composition at a temperature for a first predetermined time period;
(V) where the process also includes the step of adding amylase and cellulase enzymes to the composition.

  An amylase enzyme is considered to be any enzyme suitable for converting starch to sugar. Cellulase enzymes are also considered to be any enzyme suitable for converting cellulose or hemicellulose to sugar.

  Injecting the high velocity transport fluid through the nozzle into the composition can include creating a low pressure region formed downstream of the nozzle.

  The condensation step can be initiated by condensing the transport fluid downstream of the low pressure region.

  Transferring the composition to the holding container can include passing the composition through a temperature conditioning unit to raise the temperature of the composition to a first predetermined temperature.

  The first predetermined temperature can be between 80 and 85 degrees Celsius. The first predetermined temperature can be 83 degrees Celsius.

  Alternatively, the first predetermined temperature can be between 72 and 80 degrees Celsius, preferably between 76 and 78 degrees Celsius, for example, 75 degrees Celsius, or 77 degrees Celsius.

  The liquefaction enzyme (s), eg, amylase and / or cellulase enzymes, can be added to the composition prior to the composition being directed into the passage of the fluid treatment device.

The process can further include: Ie
(i) transferring the composition to a second holding container at the end of the first time period; and
(ii) holding the composition in a second holding container at a second predetermined temperature for a second predetermined time period, wherein a liquefying enzyme, for example an amylase enzyme, the composition being a fluid The composition can be added to the composition prior to being directed into the processor passage, and another liquefying enzyme, eg, a cellulase enzyme, can be added at the end of the first time period and for the second time period. It can be added to the composition during the beginning.

  Prior to transferring the composition to the second holding container, the process may further comprise cooling the composition to a second predetermined temperature.

  The first predetermined temperature can be between 80 and 85 degrees Celsius. If possible, the first predetermined temperature may be 83 degrees Celsius.

  The second predetermined temperature can be between 50 and 60 degrees Celsius. If possible, the second predetermined temperature may be 55 degrees Celsius.

Prior to transferring the composition to the second holding container, the process may further include: (I) directing the composition into the passage of the second fluid treatment device; and (ii) injecting a high-speed transport fluid into the composition through a nozzle communicating with the passage of the second fluid treatment device, thereby Applying a shear force to the composition such that the working fluid is subdivided during the second time and a second vapor and droplet flow pattern is formed downstream of the nozzle. Where the cellulase enzyme is added to the composition prior to the composition being directed into the passage of the first fluid treatment device, and the liquefying enzyme, eg, the amylase enzyme, is It is added to the composition prior to being guided into the passage of the two fluid treatment devices.

  The first predetermined temperature can be between 50 and 60 degrees Celsius. Preferably, the first predetermined temperature may be 55 degrees Celsius.

  The second predetermined temperature can be between 80 and 85 degrees Celsius. Preferably, the second predetermined temperature may be 83 degrees Celsius.

The process can further include the following steps. (I) cooling the composition to a predetermined fermentation temperature;
(Ii) adding one or more fermentation agents to the composition, transferring the composition to the fermentation vessel; and (iii) the composition in the fermentation vessel at a predetermined fermentation temperature for a predetermined fermentation time. To hold.

  The cooling step can include passing the composition through a cooling vessel. The cooling vessel may be a mash cooler.

  The fermentation temperature can be between 30 and 40 degrees Celsius. Preferably, the fermentation temperature may be 35 degrees Celsius.

  In the present invention, one or more fermentation agents can be added to the composition. As used herein, “fermentation agents” include well-known agents used to facilitate the fermentation process and include, but are not limited to, glucoamylase and yeast.

  The process can further include distilling the fermented composition to remove alcohol from the remainder of the composition.

The process can further include the following steps. Ie
(i) Returning the recovered water or condensate to the composition flowing into the passage of the first fluid treatment device.

The process can further include the following steps. Ie
(i) transferring the remainder of the composition to a separator; and
(ii) separating the solid (solid) from the rest of the composition.

The process can further include the following steps. Ie
(i) recovering moisture from the separator; and
(ii) returning moisture to the composition flowing into the passage of the first fluid treatment device.

The process can further include the following steps. Ie
(i) directing a portion of the composition to flow into the passage of the second fluid treatment device;
(ii) injecting a high velocity transport fluid into the composition through a nozzle in communication with a passage of the second fluid treatment device, whereby the transport fluid is subdivided into a working fluid and a second vapor And applying a shear force to the composition so that the flow pattern of the droplets is formed downstream of the nozzle,
(iii) condensing the flow pattern of the second vapor and droplets, and transferring the composition to a second holding vessel; and
(iv) holding the composition in a second holding container at a second predetermined temperature for a second predetermined time period;
(v) Therefore, the first fluid processing device and the first holding container, and the second fluid processing device and the second holding container are operated in parallel (operate), and
(vi) An amylase enzyme is then added to the composition prior to inducing the composition in the passage of the first fluid treatment device, and the cellulase enzyme is added to the composition of the composition in the passage of the second fluid treatment device. Added to one portion of the composition prior to inducing the portion.

The process can further include the following steps. Ie
(i) cooling each part of the composition to a predetermined fermentation temperature;
(ii) adding one or more fermentation agents to the composition;
(iii) transferring a portion of the composition to the fermentation vessel; and
(iv) holding the composition in a fermentation vessel at a predetermined fermentation temperature for a predetermined fermentation time.

  The fermentation temperature can be between 30 and 40 degrees Celsius. Preferably, the fermentation temperature may be 35 degrees Celsius.

  In this embodiment, one or more fermentation agents can be added to the composition. Preferably, two fermentation agents are added and the fermentation agents are glucoamylase and yeast.

  Fermentation of the first and second parts of the composition can be carried out in a single fermentation vessel. Alternatively, fermentation of one part of the composition can be accomplished in separate fermentation vessels.

  The process can further include distilling the fermented composition to remove alcohol from the remainder of the composition.

The process can further include the following steps. (I) transferring the remainder of the composition to the separator; and (ii) separating the solid from the remainder of the composition.

The process can further include the following steps. Ie
(i) recovering solids from the separator; and
(ii) returning solids to the second portion of the composition in the passage of the second fluid treatment device.

  The second part of the composition can be the solids recovered from the separator.

  The transport fluid may be steam.

  The working fluid can be water.

  Biomass can include one or more starch-based crops.

According to a second aspect of the present invention there is provided a system for the treatment of a composition comprising biomass and working fluid, the system comprising: (I) at least one fluid treatment device, having a passage for receiving a supply of the composition, and a nozzle outlet opening in the passage, and having a cross-sectional area at a throat portion An apparatus having a transport fluid nozzle having a smaller one than that of the outlet;
(Ii) a first holding container in the fluid communicating with the outlet of the passage; and (iii) a fermentation container in the fluid communicating with the first holding container.

  The system can further include a first cooling vessel positioned intermediate the first holding vessel and the fermentation vessel.

  The system can further include a second holding vessel and a second cooling vessel intermediate the first cooling vessel and the fermentation vessel.

  The fluid treatment device can include one or more additive ports to introduce the additive into the composition. An additional port can lead to the passage upstream of the nozzle outlet. Alternatively or additionally, an additional port can lead to the passage immediately downstream of the nozzle outlet. The system can further include an additional port near the second holding container.

  The system further includes a second fluid processing apparatus and a second holding container downstream of the first holding container, a second fluid processing apparatus having a second passage for receiving a composition from the first holding container. And a second transport fluid nozzle having a nozzle outlet opening in the second passage and having a throat portion having a cross-sectional area smaller than that of the outlet.

In another embodiment, the system includes a first processing line comprised of a first fluid processing device and a first holding vessel, and the system further includes a second processing line that includes: Ie
(i) a second fluid treatment device, the second fluid treatment device having a second passage for receiving the supply of the composition, and a nozzle outlet opening in the second passage, and a throat portion And having a second transport fluid nozzle whose cross-sectional area is smaller than that of the outlet, and
(ii) a second holding container in fluid communication with the outlet of the second passage;
(iii) Thus, the first and second treatment lines are connected in parallel between the composition supply and the fermentation vessel.

  The system further includes a mixing vessel in fluid communication with an inlet to the passage of the fluid treatment device, which can include mixing the biomass and working fluid supplies to form a composition.

  The system may further include a pump upstream of that or each fluid treatment device.

  The system can include a plurality of fluid treatment devices connected in series and / or in parallel to each other to form an array.

  The system can include a plurality of second fluid treatment devices connected in series and / or in parallel to each other to form an array.

  The system can further include a temperature adjustment unit for raising the temperature of the composition between the first and / or second fluid treatment device and its respective first and / or second holding vessel. .

  The system can further include a distillation apparatus downstream of the fermentation vessel. The system can further include a distillation apparatus downstream of the inlet of the mixing vessel. The system can further include a first return line connecting the distillation apparatus to the inlet of the fluid treatment apparatus.

  The system can further include a separation device downstream of the distillation device. The system can further include a separation device downstream of the inlet of the mixing vessel. The system can include a second return line that connects the separator to the inlet of the fluid treatment device.

  Separation devices include centrifuges.

  The system may further include a transport fluid supply unit in fluid communication with the or each transport fluid nozzle. The transport fluid supply unit can supply transport fluid to both the first and second fluid treatment devices.

  The transport fluid can be steam and the conditioning unit can be a steam generator.

In another embodiment, the present invention provides bioethanol produced according to any of the methods or systems disclosed herein. For example, the present invention includes a process for producing bioethanol from biomass, which includes: Ie
(a) inducing at least a first portion of the composition comprising biomass and working fluid to flow into the passage of the fluid treatment device;
(b) injecting a high-speed transport fluid into the composition through a nozzle in communication with the passage of the fluid treatment device, whereby the transport fluid is subdivided into working fluid and the flow pattern of vapor and droplets Applying a shear force to the composition so that it is formed downstream of the nozzle;
(c) condensing vapor and droplet flow patterns;
(d) transferring the composition to a first holding container;
(e) holding the composition in a first holding container at a first predetermined temperature for a first predetermined time period, wherein the liquefied enzyme is added to the composition prior to or during the process. ,
(f) transferring the composition to a second holding container after the end of the first predetermined period;
(g) maintaining the composition in a second holding container at a second predetermined temperature for a second predetermined time period;
(h) cooling the composition to a predetermined fermentation temperature;
(i) adding a fermenting agent to the composition;
(j) transferring the composition to a fermentation vessel; and
(k) Hold the composition in a fermentation vessel at a predetermined fermentation temperature for a predetermined fermentation time so as to produce a fermented composition containing bioethanol.

Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings. The drawings are as follows:
It is a longitudinal cross-sectional view of the fluid processing apparatus according to this invention. 1 is a schematic view of a first embodiment of a system for treatment of biomass composition according to the present invention. FIG. FIG. 3 is a schematic view of a second embodiment of a system for treatment of biomass composition according to the present invention. FIG. 4 is a schematic view of a third embodiment of a system for treatment of biomass composition according to the present invention. FIG. 6 is a schematic view of a fourth embodiment of a system for treatment of biomass composition according to the present invention. FIG. 6 is a schematic view of a fifth embodiment of a system for treatment of biomass composition according to the present invention. FIG. 7 is a schematic view of a sixth embodiment of a system for treatment of biomass composition according to the present invention. 2 is a graph showing fluctuations in pressure and temperature when a biomass composition passes through the fluid treatment apparatus shown in FIG.

  Detailed description of the drawing. FIG. 1 is a fluid treatment apparatus, generally designated 10 and is a vertical cross section thereof. The processing apparatus 10 includes a housing 12 in which a longitudinally extending passage 14 is defined. The passage has an inlet 16 and an outlet 18 and is a substantially constant circular cross section. In other words, the cross-sectional area of the passage 12 is substantially constant from the inlet 16 to the outlet 18.

  Projection 20 extends axially from inlet 16 into housing 12 and externally defines a plenum 22 for introduction of compressible transport fluid. The plenum 22 includes an inlet 24 that can be connected to a source of transport fluid (not shown in FIG. 1). The protrusion 20 internally defines an upstream portion of the inlet 16 and the passage 14. The protrusion 20 has a distal end 26 that is remote from the inlet 16. The distal end 26 of the protrusion 20 has a thickness that increases and then decreases again to define a surface 28 that tapers inside. The housing 12 has a wall 30, which is a location near the tapering surface 28 of the protrusion 20, which increases in thickness. This increase in thickness provides a portion of the wall 30 with a surface 32 having an inner taper corresponding to that of the tapered surface 28 of the protrusion 20. Between them, the tapered surface 28 of the protrusion 20 and the tapered surface 32 of the wall 30 define an annular nozzle 34. The nozzle 34 has a nozzle inlet 36 in fluid communication with the plenum 22, a nozzle outlet 40 opens into the passage 14, and a nozzle throat 38 is interposed between the nozzle inlet 36 and the nozzle outlet 40. The nozzle throat 38 has a smaller cross-sectional area than either the nozzle inlet 36 or the nozzle outlet 40. The passage 14 also includes a mixing region 17, which is located in the passage immediately downstream of the nozzle outlet 40.

  FIG. 2 shows a first preferred system embodiment for the treatment of biomass compositions incorporating a fluid treatment device of the type shown in FIG. A biomass composition is a composition comprising biomass and a working fluid. In the embodiments described herein, the preferred working fluid is water, but other fluids suitable for performing the process can be used. The term “biomass” is used herein to describe any biological material that can be used as a fuel or energy source. Non-limiting examples of suitable types of biomass include forest products, untreated wood products, energy crops, miscellaneous timber, short rotation coppice, and food processing and high energy crops such as animal Included are industrial and biodegradable local products such as excreta, rapeseed (grass), sugar cane and corn (maize). However, without being limited to this particular type of biomass, for example, the most preferred biomass for use in the systems and methods of the present invention are starch-based crops such as corn, wheat and barley. Biomass can be provided for use in the systems and methods of the present invention in a pre-ground form.

  The treatment system includes a holding vessel 52, indicated generally at 50, in fluid communication with the fluid treatment device 10 and the outlet 18 of the fluid treatment device 10. Holding vessel 52 is preferably insulated and surrounded by a heated water jacket (not shown) and includes a motor driven agitator (not shown) to mix and agitate the contents of vessel 52. The system 50 also includes a cooling vessel 54 in fluid communication with the holding vessel 52 and a fermentation vessel 56 in fluid communication with the cooling vessel 54. The transport fluid supply 58 is connected to the plenum inlet 24 of the processing apparatus 10 so that transport fluid is supplied thereto. Although not shown, the system can also include a pump upstream of the fluid treatment device for directing fluid into the passage 14 of the treatment device 10. Similarly, a temperature control unit (TCU) (not shown) can be included in the system 50 between the fluid treatment device 10 and the holding vessel 52. The TCU includes one or more fluid treatment devices of the type illustrated in FIG. If there are more than one processing unit in the TCU, they are preferably arranged in series. The temperature adjustment unit can also slowly increase the temperature of any fluid that passes from the fluid treatment device 10 to the holding container 52.

  The system 50 enclosed in the dotted line in FIG. 2 can be installed in an existing biomass processing line, or additional components can be added to the system 50 to create a complete biomass processing line, as needed. Can do. In this case, the system can also include a mixing vessel 60 positioned upstream of the processing device 10 and in fluid communication with the inlet 16 of the device 10. Mixing vessel 60 is preferably surrounded by a heated water jacket (not shown) and has a motor driven agitator (not shown) to mix and agitate the contents of vessel 60. The mixing vessel 60 also includes first and second additional lines 62, 66 that connect to respective first and second additional supplies 64, 68. The system can include third and fourth additional lines 70, 74 that connect to the fermentation vessel 56 to supply fermentation agents from the third and fourth additional supplies 72, 76. The distillation vessel 80 may be connected in fluid communication with the fermentation vessel 56. In addition, a holding tank (not referenced) positioned between the fermentation vessel 56 and the separation vessel 90 can be provided. The distillation vessel 80 has an outlet 84 and can include a return line 82 in fluid communication with the inlet 16 of the processing apparatus 10, either directly or through the mixing vessel 60, as shown in FIG. . Finally, the system 50 can also include a separation vessel 90 connected in fluid communication to the distillation vessel 80. Separation vessel 90 preferably includes a centrifuge and includes a second return line 92 and a drain line (drain) 94. Similar to the return line 82 of the distillation vessel 80, the second return line 92 is in fluid communication with the inlet 16 of the processing apparatus 10 either directly or via the mixing vessel 60. The drain line 94 takes out or discharges the contents in the separator 90.

  FIG. 3 shows a second embodiment of the system, generally indicated at 150. The system 150 includes a fluid handling mechanism 10 of the type shown in FIG. 1 and a first holding vessel 52 in fluid communication with the outlet 18 of the processing apparatus 10. The system 150 also includes a cooling vessel 54 in fluid communication with the first holding vessel 52 and a fermentation vessel 56 downstream of the cooling vessel 54. A transport fluid supply 58 connects to the plenum inlet 24 of the processing apparatus 10 so that transport fluid can be supplied thereto. Where the second embodiment differs from the first embodiment, the system 150 further includes a second holding vessel 152 and other components of the system 150 between the first cooling vessel 54 and the fermentation vessel 56. A second cooling vessel 154 connected in series. Both first and second holding containers 52, 152 are preferably insulated and surrounded by a heated water jacket (not shown), and each is for mixing and stirring the contents of containers 52, 152 Includes a motor driven stirrer.

  In the system 150, a first additional feed 164 is connected to the inlet 16 of the processor 10 by a first additional line 162, and a second additional feed 168 is a second additional feed Connected to the second holding container 152 by line 166. The system 150 also includes third and fourth additional lines 70, 74 that connect to the fermentation vessel 56 to supply it with fermentation agents from third and fourth additional supplies 72, 76 Can do.

  The system 150 enclosed within the dotted line in FIG. 3 can be installed in an existing biomass processing line, or additional components can be added to the system 150 to create a complete biomass processing line, if desired. Can be added. In this case, the system can also include a mixing vessel 60 positioned upstream of the processing apparatus 10 and in fluid communication with the inlet 16 of the apparatus 10. Mixing vessel 60 is preferably surrounded by a heated water jacket (not shown) and has a motor driven agitator (not shown) to mix and agitate the contents of vessel 60. When the mixing vessel 60 forms part of the system 150, the first additional line 162 can be connected to the mixing vessel 60 instead of the inlet of the fluid treatment device 10. The distillation vessel 80 can be connected to the outlet 160 of the fermentation vessel 56. The distillation vessel 80 has an outlet 84 and also includes a return line 82 that is in fluid communication with the processing device inlet 16 either directly or as shown, via the mixing vessel 60 as shown in FIG. Can do. Finally, the system 150 can include a separation vessel 90 that is in fluid communication with the distillation vessel 80. Separation vessel 90 preferably includes a centrifuge and includes a second return line 92 and a drain line 94. Similar to the return line 82 of the distillation vessel 80, the second return line 92, either directly or through the mixing vessel 60, is in fluid communication with the inlet 16 of the processing apparatus. The drain line 94 allows the contents in the separator 90 to be removed or discharged.

  4-7 show other preferred embodiments of the system of the present invention. Similar to the first and second embodiments of the system, these additional embodiments of the system can be supplemented using the mixing, distillation and separation vessels shown in FIGS. 2 and 3, however, These supplemental containers are not illustrated or described with respect to these further embodiments for reasons of brevity.

  FIG. 4 shows a third embodiment of the system of the present invention, indicated generally at 250. The system 250 includes a fluid handling mechanism 10 of the type shown in FIG. 1 and a first holding vessel 52 in fluid communication with the outlet 18 of the processing apparatus 10. The system 250 also includes a cooling vessel 54 that is in fluid communication with the fermentation vessel 56, both of which are downstream of the first holding vessel 52. The transport fluid supply 58 is connected to the plenum inlet 24 of the processing apparatus 10 so that transport fluid can be supplied thereto. The third embodiment differs from the previous embodiment in that the system 250 further includes a second fluid treatment device 210 and other components of the system 250 between the first holding vessel 52 and the cooling vessel 54. A second holding container 252 connected in series. The second processing device 210 has a second transport fluid supply 258 that is substantially identical to the first processing device 10 illustrated in FIG. 1 and connected to its respective plenum inlet.

  In the system 250, the first additional feed 264 is connected to the inlet 16 of the first processing unit 10 by a first additional line 262, while the second additional feed 268. Is connected to the inlet of the second processor 210 by a second additional line 266. The system 250 also includes third and fourth additional lines 70, 74 connected to the fermentation vessel 56 to supply fermentation agents from the third and fourth additional supplies 72, 76 Can do. The fermentation vessel 56 has an outlet 260.

  FIG. 5 shows a fourth embodiment of the system of the present invention, generally designated 350. System 350 includes first and second processing lines that are parallel to each other and connected to a shared fermentation vessel 56 positioned downstream. The first processing line includes a first fluid processing device 10 of the type shown in FIG. 1, a first holding vessel 52 in fluid communication with the outlet 18 of the first processing device 10, and a first holding vessel 52. A first cooling vessel 54 in fluid communication is included. The first transport fluid supply 58 is connected to the plenum inlet 24 of the first processing apparatus 10 so that transport fluid can be supplied thereto. The second processing line also includes a second fluid processing device 310 of the type shown in FIG. 1, a second holding vessel 352 in fluid communication with the outlet of the second processing device 310, and a second holding vessel 352. A second cooling vessel 354 is in fluid communication. The system 350 can include a second transport fluid supply 358 to supply transport fluid to the plenum inlet of the second processing device 310.

  Both first and second cooling vessels 54, 354 are in fluid communication with a fermentation vessel 56 positioned downstream.

  In the system 350, the first additional feed 364 is connected to the inlet 16 of the first processor 10 by a first additional line 362, while the second additional feed 368 is A second additional line 366 connects to the inlet of the second processing device 310. System 350 includes third and fourth additional lines 70, 74 connected to fermentation vessel 56 to supply fermentation agents to it from third and fourth additional supplies 72, 76 Can do. The fermentation vessel 56 has an outlet 360 that can connect the fermentation vessel 56 to a distillation vessel and separation vessel of the type shown in FIG. 2 to supplement the system. In the system 350, if a distillation vessel and a separation vessel are present, the system 350 can include respective return lines (not shown) that connect the distillation and separation vessel to the inlet of the second processing device 310. The system 350 can also include a mixing vessel (not shown) upstream of the first and second processing lines, otherwise the first and second processing lines for each of the first and second processing lines. Serve mixing vessel.

  Figures 6 and 7 show fifth and sixth embodiments of the system according to the invention. The system is generally designated 450 and 550 and is similar to the system 50 shown in FIG. Each has a holding vessel 52, a cooling vessel 54 in fluid communication with the holding vessel 52, and a fermentation vessel 56 in fluid communication with the cooling vessel 54. The difference between the systems 450, 550 from the system of implementation described above relates to the fluid treatment device. Instead of a single fluid treatment device upstream of the holding vessel 52, each system 450, 550 utilizes an array of fluid treatment devices.

  In a fifth embodiment system 450, a fluid treatment device 10 is provided in which the devices 10 are placed in series with each other upstream of the holding vessel 52. As illustrated in FIG. 6, an array of processing devices can share a single transport fluid supply 58, otherwise each processing device has its own dedicated transport fluid supply. be able to. The system 450 can include respective first and second additional lines 464, 468 that connect the respective first and second additional lines 462, 466 of the fluid treatment device 10. Connect to inlet 16 in an array. Similar to the previous embodiment, the third and fourth additional lines 70, 74 are connected to the fermentation vessel 56 to connect the respective third and fourth additional feeds 72, 76 to the fermentation vessel 56. Can exist at 450.

  In a sixth embodiment system 550, an array of fluid treatment devices 10 is provided, which are arranged in parallel upstream of the first and second holding vessels 52 of the device 10. An array of processing devices can share a single transport fluid supply, otherwise each pair of processing devices has a respective first and second transport fluid supply 58, as shown in FIG. Can have 558. Equally, each individual device 10 can have its own dedicated supply of transport fluid. The system 550 includes first and second additional lines 562 that connect respective first and second additional supplies 564, 568 to the inlet 16 of the fluid treatment device 10 in each pair forming the array. , 566. Similar to the previous embodiment, the third and fourth additional lines 70, 74 are connected to the fermentation vessel 56 to connect the respective third and fourth additional feeds 72, 76 to the fermentation vessel 56. Can exist at 450.

  A preferred embodiment of a process for the treatment of a composition comprising biomass and working fluid will now be described with reference to the accompanying drawings.

  The first embodiment of the process utilizes the first embodiment of the system 50 illustrated in FIG. The composition to be treated comprises a mixture of biomass and working fluid. As noted above, biomass can be obtained from a wide variety of sources, but it is preferred that the biomass is a starch-based crop (eg, corn). Also, as mentioned above, the working fluid is preferably water. Biomass and working fluid can be combined to form a composition at a location remote from the system 50. Alternatively, if the system 50 includes a mixing vessel 60, the composition can be formed with the mixing vessel 60. The basic starch-based crop is introduced into the working fluid in the mixing vessel 60 at an additional flow rate of controlled mass. The introduction of the crop can be done manually or automatically and can be introduced continuously or as a batch. The mixing of crop and working fluid leads to a composition that forms a slurry. Separately, the amylase and cellulase enzymes retained in the first and second additional feeds 64, 68 are transferred to the composition via respective first and second additional feed lines 62, 66. Added. Preferably, the ratio of crop to liquid content in the slurry is 20-40% by weight. Optionally, one or more PH regulators (adjusters) (eg, dilute sulfuric acid, ammonia) and / or surfactants can be added to the slurry in this regard.

  The amylase enzyme utilized in each of the treatment process examples described herein is preferably an α-amylase having an activity between 750 and 824 AGU / g. Enzyme activity is expressed per unit mass of wet crop or feedstock.

  Heated water is placed in a water jacket surrounding the mixing vessel 60, and the heated water jacket then heats the slurry in the vessel 60, typically to a temperature of 30-60 ° C, most preferably 30-40 ° C, and 30 -Hold mud at this temperature for 120 minutes. While the slurry is held in the mixing vessel 60, the motor driven agitator agitates the slurry with gentle (ie low shear) agitation.

  The slurry is held at the desired temperature in the mixing vessel 60 for a sufficient period of time to allow the starch content to be prepared for complete hydration. When the slurry is soaked in the mixing vessel 60 for a sufficient amount of time, it is drained from the vessel 60 and directed through the inlet 16 into the passage 14 of the fluid treatment device 10. The composition can be directed to the fluid treatment device 10 under gravity. Alternatively, if a pump is present, the pump can direct the composition to the fluid treatment device 10 under low shear conditions.

  Referring to FIG. 1, when the slurry reaches the fluid treatment device 10, the slurry enters the passage 14 through the inlet 16 and passes out through the outlet 18. The transport fluid, in this non-limiting example, is preferably steam and is fed from the transport fluid supply 58 at a preferred pressure between 5-7 Bar to the plenum inlet 24. The introduction of the transport fluid through the inlet 24 and plenum 22 causes the vapor injection to be very high, preferably exiting the nozzle outlet 40 at an ultrasonic rate. When steam is injected into the slurry, momentum and mass transfer occur between the two to form a flow pattern of steam and droplets, resulting in subdivision of the working fluid components of the slurry. In other words, the working fluid in the composition breaks down into very small droplets that are dispersed in a continuous gas phase. This movement is enhanced by the expansion of steam through the turbulence generated in the mixing region 17 of the passage 14 as it exits the nozzle 34. The steam injected into the mixing zone 17 not only applies shear forces to the slurry and breaks down the working fluid components, but also disrupts the basic crop cellular structure suspended in the slurry. This disruption of cellular structure separates any starch granules present from the crop while at the same time exposing as much of the lignocellulosic material present in the composition as possible.

  The temperature and pressure of the composition such that the composition passes through the fluid treatment device 10 can be seen in the graph of FIG. 8, which shows when the composition passes through various points in the device 10 of FIG. Shows temperature and pressure profiles (sides). The graph is divided into four sections (sections) A-D, which correspond to the various sections of the device 10. Section A corresponds to the section of passage 14 between inlet 16 and nozzle 34. Section B corresponds to the section upstream of the mixing region 17 that extends between the nozzle 34 and the middle portion of the mixing region 17. Section C corresponds to the aforementioned intermediate portion of the mixing zone 17 and the downstream section of the mixing zone 17 extending between the outlets 18 while section D is its temperature and pressure as the composition passes through the outlet 18 Is illustrated.

  Steam is injected into the composition at the beginning of section B of the graph of FIG. Its expansion at the injection of steam, preferably at supersonic speed and at the exit of nozzle 34, creates a low pressure area in the section of mixing region 17 immediately downstream of nozzle 34. At a point determined by the steam and geometric conditions, and the rate of heat and mass transfer, the steam speed decreases and the steam begins to condense. Vapor condensation can continue and a condensation shock wave can be formed in the downstream section of the mixing zone 17. As can be seen in section C of FIG. 8, the formation of a condensed shock wave causes a rapid increase in the pressure of the composition and the composition condenses into the liquid phase in section D of FIG.

  As described above, when steam is injected into the composition through the nozzle 34, a pressure decrease may occur in a section upstream of the mixing zone 17. This reduction in pressure creates at least a partial vacuum in this upstream section of the mixing region 17 near the nozzle outlet 40. Tests have shown that approximately 90% vacuum is achieved in region 17 when steam is injected.

  As previously mentioned, shear forces are applied to the composition by the injected steam, and the subsequent turbulence created disrupts the basic crop cell structure suspended in the slurry. As the slurry passes through the partial vacuum formed in the mixing region 17 and the condensed shock wave, it is further broken by changes in pressure generation, as illustrated by the pressure profile in sections B and C of FIG. Is done.

  When the starch granules are separated from the crop in the device 10, the granules are further hydrated, heated and activated almost immediately for the introduction of steam. The apparatus 10 simultaneously pumps and heats the composition to complete the hydration and to activate or gelatinize the starch contents as the slurry passes. In other words, homogenous expansion of starch granules occurs due to granules that absorb water in the presence of heat. This causes hydrogen bonding between the starch polymers within the granules to loosen, and there is irreversible fracture of the crystal structure inside the granules.

  In addition, the device mixes the amylase and cellulase enzymes into the composition and provides a high level of contact with the starch and lignocellulose materials in a homogeneous distribution and liquid phase. The temperature of the composition is preferably between 74-76 ° C. as it leaves the device 10.

  The composition is selected so that the temperature upon leaving the device 10 avoids any thermal damage to the composition during activation of starch content and cell destruction. However, this temperature may be lower than that for optimal performance of amylase and cellulase enzymes. The temperature of the composition may therefore need to be increased without subjecting the composition to extremely high temperatures or additional shear forces. This gentle heating can be achieved using an optional temperature control unit (TCU) positioned between the device 10 and the holding vessel 52.

  As mentioned above, a TCU includes one or more fluid treatment devices of the type illustrated in FIG. The pressure of the steam supplied to the device that creates the TCU is controlled so that the pressure of the steam is relatively low when compared to that supplied to the fluid treatment device 10 upstream of the TCU. The preferred steam input pressure for the TCU device is between 0.5-2.0 bar. As a result, when the composition passes through the TCU, the transport fluid velocity is so low that there is little or no shear, or a condensation impact is applied to the composition by the injected vapor. Instead, the TCU simply uses low pressure steam to gently raise the temperature of the composition.

  Once it passes through the TCU, the composition is preferably at a temperature between 80-85 ° C and most preferably at 83 ° C. The water jacket of the holding vessel 52 receives heated water that maintains the slurry at the aforementioned temperature. If no TCU is present in the system 50, the heated water jacket is used to raise and then maintain the slurry temperature within the desired range. The composition is held in holding container 52 for a residence time sufficient to allow amylase and cellulase enzymes to convert the starch, cellulose and hemicellulose present to sugar. At the end of the residence time, the composition is transferred to the fermentation vessel 56. In this way, the method and system of the present invention can be used to generate polysaccharides from biomass, which can be further expanded to alcohols, such as, for example, ethanol, especially bioethanol, if necessary. May be processed.

  Suitable temperatures for the composition for fermentation are between 30 and 40 ° C, and most preferably 35 ° C. In order to lower the temperature of the composition between the holding vessel 52 and the fermentation vessel 56, the composition can be passed through a cooling vessel 54 that operates in a manner similar to a conventional mash cooler. Alternatively, if the cooling vessel 54 is not present, the composition can be left to cool to the desired temperature in the fermentation vessel 56.

  The fermentation agent is preferably added to the composition either at fermentation vessel 56 or immediately upstream thereof. The drug is contained in the third and fourth additional supplies 72, 76 and is delivered to the composition via respective additional lines 70, 74. Fermentation agents used can be glucoamylase and yeast. Once the drug is added and the composition is within the desired temperature range, the composition has sufficient time to allow the drug to convert the sugars present to alcohol, such as bioethanol. Meanwhile, it is held in the fermentation vessel within the desired temperature range.

  Once the fermentation stage is complete, the composition can be transferred for subsequent distillation and separation. As previously mentioned, these subsequent processes may or may not be part of the system and method of the present invention. In the distillation vessel 80, the composition boils and any alcohol (ethanol) present in the composition evaporates and is discharged through the outlet 84. A molecular sieve can be provided downstream of the outlet to remove any impurities remaining in the alcohol. Moreover, a water recovery system (not shown) positioned between the distillation vessel 80 and the separator (separator) vessel 90 can be provided. The remainder of the composition left in the distillation vessel 80 is known as the “whole stillage”. This entire distillation effluent is made up of two main components: the non-starch element of the basic crop (also known as “distiller's grains”) and water (also known as “diluted distillation effluent ( thin stillage) ”. This entire distillation waste solution is transferred from the distillation vessel 80 to the separation vessel 90, so that the distillation residue and the dilute distillation waste solution can be separated from each other. Separation is preferably accomplished using a centrifuge. The separated distillate waste liquor can be added to the composition via return line 92 as needed. Distilled waste can be processed and used as animal feed.

  The process employed by the second implementation of system 150 is similar to that employed by the first implementation of system 50, as shown in FIG. The composition to be treated comprises a mixture of biomass and working fluid. The preferred biomass is a starch-based (base) crop (eg corn) and the working fluid is preferably water. Biomass and working fluid may be mixed to form a composition at a remote location with the system 150. Alternatively, if the system 150 includes a mixing vessel 60, the composition can be formed in the mixing vessel 60. Basic starch-based crops are introduced into the working fluid in the mixing vessel 60 at an additional flow rate of controlled mass. Mixing crops and working fluids leads to extraneous matter that forms a slurry. Alternatively, the amylase enzyme retained in the first additional feed 164 is further added to the composition via the first additional feed line 162. The first additional line 162 can supply amylase enzyme directly to the mixing vessel 60 when present, or to the inlet 16 of the fluid treatment device 10. Preferably, the percentage of the crop to the liquid content in the slurry is 20-40% by weight. Optionally, one or more PH modifiers (adjusters) and / or surfactants can be added to the slurry at this point.

  The heated water is placed in a water jacket surrounding the mixing vessel 60, and the heated water jacket then heats the slurry in the vessel 60 to a temperature generally between 30-60 ° C, most preferably 30-40 ° C, and the slurry is removed. Hold at this temperature for 30-120 minutes. While the slurry is held in the mixing vessel 60, the motor driven agitator stirs the slurry with gentle (ie, low shear) agitation.

  The slurry is held at the desired temperature in the mixing vessel 60 for a sufficient period of time to allow the starch content to be prepared for complete hydration. When the slurry is soaked in the mixing vessel 60 for a sufficient amount of time, it is discharged from the vessel 60 and directed via the inlet 16 to the passage 14 of the fluid treatment device 10. The composition can be directed to the fluid treatment device 10 under gravity. Alternatively, if a pump is present, the pump can direct the composition into the fluid treatment device 10. In this case, a low shear pump is used. The fluid treatment device 10 is the same as that used in the first embodiment of the process. The mode of operation of the device 10, the mechanisms that occur therein, and the resulting effects on the composition are as in the first embodiment of the process, as described above with respect to FIGS. . They are therefore not detailed here again.

  Once the starch granules are separated from the crop in the device 10, the granules are further hydrated, heated and activated almost immediately for the introduction of steam. The device 10 simultaneously pumps and heats the composition to complete hydration and activate or gelatinize the starch content as the slurry passes. Moreover, the device mixes the amylase enzyme into the composition and provides a homogeneous distribution and high level of contact with the starch material in the liquid phase. When the composition leaves device 10, the temperature is preferably between 74-76 ° C.

  Similar to the first embodiment of the process, a temperature control unit (TCU) of the type described above can be included in system 150 to gently raise the temperature of the composition as previously described. Once it passes through the TCU, the composition is preferably at a temperature between 80-85 ° C, and most preferably 83 ° C. The composition is then transferred to the first holding container 52. The water jacket of the first holding container 52 receives heated water that maintains the slurry at the aforementioned temperature. If a TCU is not present in the system 150, the heated water jacket is used to increase and then maintain the temperature of the slurry within the desired range. The composition is held in the first holding container 52 for a first residence time sufficient to allow the amylase enzyme to convert the starch present in the composition to sugar. At the end of the first residence time, the composition is transferred to the second holding container 152.

  The preferred temperature of the composition is between 50 and 60 ° C. and most preferably 55 ° C. as it passes through the second holding container 152. In order to reduce the temperature of the composition between the first and second holding containers 52, 152, the composition can be passed through a cooling container 54 that is operated in the same manner as a conventional mash cooler. Alternatively, if the cooling vessel 54 is not present, the composition can be cooled to the desired temperature in the second holding vessel 152. The heated water jacket of the second holding container 152 maintains the temperature of the composition within the desired range. Cellulase enzyme is added to the composition in the second holding vessel 152 via the second additional feed 168 and associated feed line 166. Cellulase enzymes are added to react with the cellulose present in the exposed lignocellulosic material and hemicellulose as the composition passes through the fluid treatment device 10. The composition is held in the second holding container 152 for a second residence time sufficient to allow all of the cellulose and hemicellulose in which the cellulase enzyme is present to be converted to sugar. At the end of the second residence time, the composition is transferred to the fermentation vessel 56.

  The preferred temperature of the composition for fermentation is between 30 and 40 ° C and most preferably 35 ° C. In order to lower the temperature of the composition between the second holding vessel 152 and the fermentation vessel 56, the composition can be passed through a second cooling vessel 154 that is operated in the same manner as a conventional mash cooler. Alternatively, if the second cooling vessel 154 is not present, the composition can be left to cool to the desired temperature in the fermentation vessel 56.

  The fermentation agent is preferably added to the composition either at fermentation vessel 56 or immediately upstream thereof. The drug is contained in the third and fourth additional supplies 72, 76 and delivered to the composition via respective additional lines 70, 74. The fermentation agent used can be glucoamylase and yeast. Once the drug is added and the composition is within the desired temperature range, the composition is within the desired temperature range for a fermentation time sufficient to allow the sugar in which the drug is present to be converted to alcohol. In the fermentation vessel.

  Once the fermentation stage is complete, the composition can be carried for subsequent distillation and separation. In the distillation vessel 80, the composition is boiled and any alcohol present in the composition, such as ethanol, is evaporated and discharged via the outlet 84. A molecular sieve can be provided downstream of the outlet to remove any residual impurities in the alcohol. In addition, a water recovery system (not shown) positioned between the distillation vessel 80 and the separator vessel 90 can be provided. The remainder of the composition left in the distillation vessel 80 is known as “total distillation waste”. This entire distillate is made up of two main components: the non-starch element of the basic crop (also known as “distilled waste”) and water (also known as “diluted distillate”) It is. This entire distillation waste solution is transferred from the distillation vessel 80 to the separation vessel 90, so that the distillation residue and the dilute distillation waste solution can be separated from each other. Separation is preferably accomplished using a centrifuge. The separated distillate waste liquor can be added to the composition via return line 92 as needed. Distilled waste can be processed and used as animal feed.

  The process employed by the third implementation of system 250 is similar to that employed by the first and second implementations of systems 50, 150, as shown in FIG. The composition to be treated is formed from a mixture of biomass and working fluid and is prepared in the same manner as described above for the second embodiment. However, it is primarily the cellulase enzyme rather than the amylase enzyme that is added to the composition from the first additional feed 264. The composition can be directed to the first fluid treatment device 10 under gravity, or the pump can be directed to the first fluid treatment device 10 under low shear conditions. Both the first and second fluid treatment devices 10, 210 employed in this process are the same as those used in the first and second embodiments described above. The manner of operation of the devices 10, 210, the mechanisms that occur therein, and the resulting effects on the composition are as described above with respect to FIGS. Therefore, they are not detailed here again.

  The first processing device 10 is mainly used to pre-treat the cellulosic material and mix it with the cellulase enzyme. The first processor 10 also partially separates the starch granules from the crop and partially hydrates the starch granules. The second processor 210 is used to fully hydrate and activate the starch and mix it with the starch enzyme. The apparatus incorporates a cellulase enzyme into the composition to provide a homogeneous distribution and high level of contact with any cellulose and hemicellulose exposed by the destruction of the lignocellulosic material in the first processing apparatus 10. When the composition leaves the first apparatus 10, the temperature of the composition is preferably between 50-60 ° C and most preferably 55 ° C. It is then transferred to the first holding container 52.

  The water jacket of the first holding container 52 receives heated water that maintains the slurry at the aforementioned temperature. The composition is held in the first holding container 52 for a first residence time sufficient for the cellulase enzyme to convert the cellulose and hemicellulose present in the composition to sugar. At the end of the first residence time, the composition is transferred to the second processor 210, where amylase enzyme is added via the second additional feed 268.

  As described above, the second fluid treatment device 210 is operated in the same manner as the first treatment device 10 with the same effect on the starch content of the composition. In addition, the device is supplied with a homogeneous distribution and high level of contact with the starch material in the liquid phase, which incorporates the amylase enzyme into the composition. When the composition leaves the second device 210, its temperature is preferably between 74-76 ° C. As mentioned above, a temperature adjustment unit can be present before the composition is transferred to the second holding vessel 252 to gently raise the temperature of the composition between 80 and 85 ° C. The water jacket of the second holding vessel 252 receives heated water that maintains the slurry at the temperature. If a TCU is not present in the system 250, a heated water jacket is used to raise the temperature of the slurry within the desired range and then maintain it. The composition is held in the second holding vessel 252 for a second residence time sufficient to allow the amylase enzyme to convert the starch present in the composition to sugar. At the end of the second residence time, the composition is transferred to the fermentation vessel 56.

  As with the previously described embodiments, the preferred temperature of the composition for fermentation is between 30 and 40 ° C, and most preferably 35 ° C. In order to reduce the temperature of the composition between the second holding vessel 252 and the fermentation vessel 56, the composition can be passed through a cooling vessel 54 that moves in the same manner as a conventional mash cooler. Alternatively, if the cooling vessel 54 is not present, the composition can be cooled to the desired temperature in the fermentation vessel 56. The fermentation stage is identical to that of the previous embodiment. Once the fermentation stage is completed, the composition can be transferred through an outlet 260 for subsequent distillation and separation stages, which may also be the same as in the previous embodiment.

  A fourth embodiment of the process uses the system 350 shown in FIG. 5, where the conversion of the starch and cellulose content of the composition to sugar is paralleled before the composition passes through the shared fermentation vessel 56. Is carried out in the first and second process lines that are driven to. A biomass and working fluid composition of the type already described above has an amylase enzyme added to it via a first additional feed 364. The resulting composition is introduced into the first process line and first into the first treatment device 10, so that it is transported by the transport fluid in the same way that the various fluid treatment devices have already been described. Subdivided. In this way, the first fluid treatment device 10 hydrates and activates the starch content of the composition and homogeneously incorporates the amylase enzyme into the composition.

  When the composition exits the first device 10, its temperature is again preferably between 74-76 ° C., and thus upon exiting the first device, via a temperature control unit or a water jacket Any of the first holding containers 52 with the slab is gently heated to the desired 80-85 ° C. range. The composition is then held in the first holding vessel 52 for a first residence time sufficient to allow the amylase enzyme to convert the starch content of the composition to sugar. The composition is then transferred to the fermentation vessel 56 for a fermentation stage of the type already described above. The cooling vessel 54 can lower the temperature of the composition prior to fermentation, otherwise the composition can be cooled in the fermentation vessel 56. After fermentation, the composition is discharged through outlet 360 for subsequent distillation and separation.

  The solids and distillate obtained from the separation stage are then combined with additional working fluid and / or liquid components that are discharged during distillation or separation to form a further batch of biomass composition. It is done. The cellulase enzyme is added to the composition, which is then directed to the second process line via the second processor 310. Furthermore, passing the composition through the second processing unit 310 results in disrupting the cellular structure of the solid material in the composition and homogeneously incorporating the cellulase enzyme into the composition, the second processing unit 310 , Operated in the same manner as already described. The composition preferably exits the second device 310 at a temperature between 50 and 60 ° C. and is transferred to the second holding container 352. The composition is held in the second holding container 352 for a second residence time sufficient for the cellulase enzyme to convert the cellulose and hemicellulose exposed in the second device 310 to sugar. The composition is then transferred via the second cooling vessel 354 as needed for fermentation in the fermentation vessel 56.

  This embodiment of the process can be modified so that a portion of the initial composition is fed to both the first and second process lines simultaneously, the first line is the starch content, and the second The line involved converting the cellulose and hemicellulose content to sugar before both parts of the composition were transferred to the fermentation vessel 56. Therefore, it is not important that the second process line receives the remainder of the composition after the separation stage.

  As used by the systems of FIGS. 2 and 3, the fifth and sixth embodiments of the process employed by the systems shown in FIGS. 6 and 7 are substantially the same as the first and second embodiments of the process. is there. The formation of the biomass composition, the addition of amylase and cellulase enzymes, the remaining of the processed composition in one or two holding vessels, and the subsequent fermentation of the composition are the first of these as their initial embodiments. The same is true in the fifth and sixth embodiments. The difference between the fifth and sixth embodiments is that a single fluid treatment device has been replaced by an array of fluid treatment devices. In the fifth embodiment of FIG. 6, the array is formed from a number of processing devices arranged in series with each other. In the sixth embodiment of FIG. 7, the array is formed from two pairs of processing devices in series, where each pair is parallel to the other. It should be understood that the number of fluid treatment devices and their configurations could be used in the process and system of the present invention.

  The operation and mechanism of each device and the effects created therein are the same as already described. Use of an array of the type shown in FIGS. 6 and 7 maximizes the effect of the processing equipment on starch content hydration and activation, lignocellulosic material disintegration and exposure, and intimate mixing of the composition with the enzyme. . The use of the array can also allow the temperature of the composition to rise gradually and higher than is possible with a single processing unit in all of the arrays. This is delivered to each subsequent device in the array to ensure that only the desired increase in temperature of the composition is achieved after the composition has passed through the final device in the array. May be achieved by changing the supply pressure and / or density of the transport fluid produced.

  Unless otherwise stated, the cooling vessel, distillation vessel and separation vessel that can be included in the system of the present invention are conventional combinations. They are therefore not described in sufficient detail in this specification.

  The present invention provides a single treatment system and process for the conversion of both starch and cellulose present in a biomass composition. In doing so, the present invention maximizes the alcohol obtained from the composition, including those from cellulose and lignocellulose materials that are necessarily transported to the processing plant with the collected crop. The cost of transporting this additional material is therefore considerably recovered with the present invention. By converting the starch and cellulose content together, the present invention provides significant cost compared to existing systems where different processes and process lines are required to convert the starch and cellulose content separately. Provide reductions.

  Further advantages are obtained with the present invention through the use of a fluid handling mechanism of the type described herein. Using a processing mechanism of the type described will allow the present invention to heat and activate the starch content of the composition, while at the extreme heat zone that may damage the starch content. You can avoid creating. Prevention of these areas also reduces or eliminates the Maillard effect due to the protein reaction with the extracted starch. These reactions can hinder the conversion of starch to sugar and thus reduce the yield. In addition, gentle rocking mixing and pumping with low shear pumps at low temperatures are also held in one of the holding containers or while being transported between containers, the starch content of the composition Ensure that there are no high shear forces that can damage the. Such damage limits the final glucose yield available from the stock.

  The processor also ensures that the components of the composition are thoroughly mixed, rather than using a simple stirrer paddle and / or recirculation loop alone. The subdivision of the working fluid further ensures a more homogeneous mixing of the composition than previously possible. This good mixing increases the efficiency of the amylase and cellulase enzymes added to convert the starch and cellulose content to sugar.

  Regarding the conversion of lignocellulosic material, shearing and condensation / pressure shocks are responsible for the biomass composition of the composition because in processing the equipment further improves the performance of the invention, this exposes more of this material present in the biomass. Applied to the element. This allows virtually all starch granules in the stock to be separated, whereby the enzyme activation is supplemented by mechanical activation in the processing unit and is improved compared to conventional processes. Provides a high starch activation rate. This also allows the process to make the starch in particular a sugar with a substantially 100% conversion rate. The method of the present invention can therefore require the composition to pass through the processing equipment only once, before it is ready to pass through the holding vessel for the conversion stage. Therefore, there is no time for loss enhancement during the process and the yield is greatly improved.

  Exposing more starch also means that less of the amylase enzyme is needed to achieve the equivalent value of 12-18 desirable glucose before the composition is transferred to the fermentation process. In addition, condensation / pressure shock kills bacteria at relatively low temperatures, thereby reducing losses in any subsequent fermentation process.

  Additionally, injecting a transport fluid, such as steam, into the biomass composition to subdivide the working fluid and build a steam and droplet flow regime, into the cellular structure of the contents of the composition, It ensures a greater degree of collapse than that achieved by existing pre-treatment processes. Furthermore, when the decay is accomplished at least in part by injecting the transport fluid, the present invention allows the reduced amount of catalyst or additive to obtain the desired degree of decay when compared to existing pre-chemical treatment processes. enable. In fact, the collapse achieved by transport fluid injection may completely eliminate the need for such pre-treatment additives. The transport fluid injection of the processing equipment ensures continuous shear and turbulent forces on the composition. The method of the present invention can therefore be continuous and does not have to include a single vessel process as it is required for a steam explosion pretreatment process.

  The high shear force provided by the high-speed transport fluid injection not only assists in the destruction of the cellular structure of the biomass, but also operates the composition to ensure intimate and homogeneous heating and mixing of the enzyme with the composition. The fluid components are also subdivided. Such improved heating and mixing reduces the time and amount of enzyme required to achieve the required chemical reaction in the holding vessel.

  It has also been discovered that the process and system of the present invention can also improve fermentation rates in subsequent fermentation processes. The improved hydration of the present invention also hydrates some protein in the biomass feedstock. These hydrated proteins serve as additional raw materials for the fermentable yeast, thereby improving the fermentation performance of the yeast.

  Although one or more cooling vessels are described as forming part of the system of the present invention, it is understood that these cooling vessels are components of the system rather than being preferred and important. Should. While the cooling vessel allowed the temperature of the composition to fall between the holding vessel and the fermentation vessel, this cooling could take place within the holding vessel or the fermentation vessel itself. Such cooling vessels can include, for example, heat exchangers, chillers, direct injection coolers, cascade coolers, or the like.

  The processor can be modified to include one or more additional ports, thereby adding the enzyme directly to the processor instead of the mixing vessel. Additional ports may be provided that lead to the passage of the device upstream of the nozzle outlet. Alternatively or additionally, an additional port can be provided in the mixing region of the passage that leads to the passage immediately downstream of the nozzle.

  The sequence of processing units utilized in the fifth and sixth embodiments of the system can replace the individual processing units shown in other illustrated implementations. In embodiments of the present invention where there are more than one fluid treatment device present, two or more of these multiple treatment devices can share a single transport fluid supply. Instead, all of the processing equipment present in the system may share a single transport fluid supply.

  While the preferred embodiments of the system described above include additional lines connecting each additional supply to the system, these are not essential to the system and method of the present invention. Each additive can be manually added to the system at the desired location without the need for a dedicated feed and associated supply line.

  It has already been mentioned that the mixing vessel is a preferred rather than important component of the system of the present invention. Equally, the initial steps in the treatment process of forming the myomas and working fluid composition in the mixing vessel are not essential. If no mixing container is present, the composition can be formed at a remote location and then pumped into the system of the present invention for treatment.

  If the enzyme used requires it, so that the temperature of the composition during its residence time in the holding vessel can be between 72 and 80 ° C, and preferably between 76 and 78 ° C, The first embodiment of the system and process can be modified.

  The preferred transport fluid used in the processes and systems of the present invention is steam. However, alternative transport fluids can be used. An alternative hot, condensable gas, such as carbon dioxide, can be used instead, for example.

  It should be understood that the method of the present invention is not limited to the use of the specific α-amylase enzymes described above. Alternative amylase enzymes such as β-amylase or λ-amylase can be used instead. Furthermore, it must be observed that more than one of each type of amylase enzyme and cellulase enzyme is added to the composition. Other enzymes, amylases, cellulases, or enzymes other than hemicellulases can act on biomass in substantially the same manner as amylases, cellulases, or hemicellulases, and are within and within the scope of the present invention. is expected.

  These and other modifications and improvements can be incorporated without departing from the scope of the invention.

Claims (74)

A method for treating biomass comprising: (a) inducing at least a first portion of a composition comprising biomass and working fluid to flow into a passage of a fluid treatment device;
(B) injecting a high velocity transport fluid into the composition through a nozzle communicating with the passage of the fluid treatment device, whereby the transport fluid is subdivided into working fluid and the flow pattern of vapor and droplets downstream of the nozzle Applying a shear force to the composition so as to form,
(C) condensing vapor and droplet flow patterns;
(D) transferring the composition to a first holding container; and (e) holding the composition in the first holding container at a first predetermined temperature for a first predetermined time where it liquefies. Adding the enzyme to the composition before or during the process.   2. The method according to claim 1, wherein the liquefaction enzyme is selected from the group consisting of starch-to-sugar convertase, cellulase or hemicellulase-to-starch convertase, and combinations thereof.   The method according to claim 2, wherein the starch-to-sugar convertase is amylase and the cellulase, or hemicellulase-to-starch convertase, is cellulase, or hemicellulase or both.   The method according to claim 1, wherein step (b) comprises generating a low pressure region formed downstream of the nozzle.   The method according to claim 1, wherein the transport fluid is a condensable gas selected from the group consisting of steam and carbon dioxide.   The method according to claim 1, wherein step (d) comprises passing the composition through a temperature adjustment unit to raise the temperature of the composition to a first predetermined temperature.   The method according to claim 1, wherein the first predetermined temperature is between 80 ° C and 85 ° C.   The method according to claim 7, wherein the first predetermined temperature is 83 ° C.   The method according to claim 1, wherein the first predetermined temperature is between 72 ° C and 80 ° C.   The method according to claim 9, wherein the first predetermined temperature is between 76 ° C. and 78 ° C.   The method according to claim 9, wherein the first predetermined temperature is 75 ° C or 77 ° C.   4. The method according to claim 3, wherein the amylase and cellulase enzymes are added to the composition prior to step (a). And (g) transferring the composition to the second holding container next to the end of the first predetermined time; and (g) transferring the composition to the second predetermined temperature in the second holding container. The method according to claim 1, comprising holding for a second predetermined period of time.   A first liquefaction enzyme is added to the composition prior to step (a), and a second liquefaction enzyme is added to the composition between the end of the first predetermined time and the beginning of the second predetermined time. A method according to claim 1, which is added.   15. The method according to claim 14, wherein the first liquefaction enzyme is amylase and the second liquefaction enzyme is cellulase or hemicellulase, or both.   14. The method according to claim 13, further comprising cooling the composition to a second predetermined temperature prior to step (f).   The method according to claim 13, wherein the second predetermined temperature is between 50 ° C and 60 ° C.   The method according to claim 17, wherein the second predetermined temperature is 55 ° C. Further, prior to the next (e ₁ ) step (f), at least a first composition is directed into the passage of the second fluid treatment device, and (e ₂ ) a second high velocity transport fluid, At least a portion of the composition is injected through a nozzle in communication with the passage of the second fluid treatment device, whereby the transport fluid is subdivided into working fluid and the second vapor and droplet flow pattern is A shear force is applied to the composition, as formed downstream of the nozzle of the second fluid treatment device, wherein the first liquefaction enzyme is added to the composition prior to step (a), and the second the liquefied enzyme is added prior to the composition step (e _1), the method according to claim 13.   The method according to claim 19, wherein the first predetermined temperature is between 50 ° C and 60 ° C.   21. A method according to claim 20, wherein the first predetermined temperature is 55 [deg.] C.   The method according to claim 19, wherein the second predetermined temperature is between 80 ° C and 85 ° C.   The method according to claim 22, wherein the second predetermined temperature is 83 ° C. further,
(H) cooling the composition to a predetermined fermentation temperature (i) adding a fermentation agent to the composition (j) transferring the composition to a fermentation vessel; and (k) a predetermined fermentation temperature in the fermentation vessel. 20. A method according to claim 19, comprising holding to produce a fermented composition at a predetermined fermentation time.   25. A method according to claim 24, wherein step (h) comprises passing the composition through a cooling vessel.   26. A method according to claim 25, wherein the cooling vessel is a mash cooler.   The process according to claim 24, wherein the predetermined fermentation temperature is between 30 ° C and 40 ° C.   The process according to claim 27, wherein the predetermined fermentation temperature is 35 ° C.   25. The method according to claim 24, wherein the fermentation agent is selected from the group consisting of glucoamylase, yeast, and combinations thereof.   25. The method according to claim 24, further comprising (l) distilling the fermented composition to remove alcohol from the remainder of the composition.   32. The method according to claim 30, further comprising: (m) returning any recovered water or condensate to the composition flowing into the passage of the first fluid treatment device. 32. The method according to claim 31, further comprising: (n) transferring any remaining composition to a separator; and (o) separating solids from the remaining composition. 33. The method according to claim 32, further comprising: (p) recovering moisture from the separator; and (q) returning moisture to the composition flowing into the passage of the first fluid treatment device. And, after the next (f ₂ ) step (e), directing at least one portion of the composition, the second portion, to flow into the passage of the second fluid treatment device,
(G ₂ ) high velocity transport fluid is injected into the second portion of the composition through a nozzle in communication with the passage of the second fluid treatment device, whereby the transport fluid is subdivided into working fluid and second Applying a shear force to the second portion of the composition such that a flow pattern of two vapors and droplets is formed downstream of the nozzle of the second fluid treatment device;
(H ₂ ) condensing the flow pattern of the second vapor and droplets, and transferring the second portion of the composition to the second holding vessel; and (i ₂ ) transferring the second portion of the composition The second holding container is held at a second predetermined temperature at a second predetermined time for a second predetermined time, wherein the first fluid processing device, the first holding container, and the second fluid processing The apparatus and the second holding vessel operate in parallel, and the amylase enzyme is added to the first part of the composition prior to induction of the first part of the composition into the passage of the first processing apparatus. And the cellulase enzyme is added prior to induction of the second portion of the composition into the passage of the second processing device. Furthermore, each part of the following (j ₂ ) composition is cooled to a predetermined fermentation temperature,
(K ₂ ) adding a fermentation agent to each part of the composition;
(L ₂ ) transferring each part of the composition to at least one fermentation vessel, and (m ₂ ) transferring each part of the composition at a predetermined fermentation temperature in a predetermined fermentation time in at least one fermentation vessel. 35. A method according to claim 34 comprising holding to form a fermented composition between.   36. A process according to claim 35, wherein the fermentation temperature is between 30 <0> C and 40 <0> C.   The process according to claim 36, wherein the fermentation temperature is 35 ° C.   36. The method according to claim 35, wherein the fermentation agent is selected from the group consisting of glucoamylase, yeast, and combinations thereof.   36. The method according to claim 35, wherein the fermentation of the first and second parts of the composition is performed in a single fermentation vessel.   36. A method according to claim 35, wherein the fermentation of the first and second parts of the composition is carried out in separate fermentation vessels.   36. The method according to claim 35, further comprising distilling the fermented composition to remove alcohol from the remainder of the composition. Further comprising transferring any remaining non-fermented portion of the next (n ₂ ) composition to a separator, and (o ₂ ) separating solids from the remaining non-fermented portion of the composition 36. A method according to item 35. Furthermore, to recover the next step (p ₂₎ solids from the separator, and a (q ₂₎ to the solids back to the passage of the second fluid treatment apparatus, according to claim 42 methods.   43. A method according to claim 42, wherein the second part of the composition is the solids recovered from the separator.   The method of claim 5, wherein the transport fluid is steam.   The method according to claim 1, wherein the working fluid is water.   The process according to claim 1, wherein the biomass comprises one or more starch-based crops. A system for processing a composition comprising biomass and a working fluid comprising: (a) at least one fluid processing device having a passage having an inlet for receiving a supply of the composition, and opening in the passage; Including a transport fluid nozzle having a nozzle outlet that has a throat portion whose cross-sectional area is smaller than that of the outlet;
(B) a first holding vessel in fluid communication with the outlet of the passage; and (c) a fermentation vessel in fluid communication with the first holding vessel.   49. The system according to claim 48, further comprising a first cooling vessel positioned intermediate the first holding vessel and the fermentation vessel.   50. The system according to claim 49, further comprising a second holding vessel and a second cooling vessel positioned intermediate the first cooling vessel and the fermentation vessel.   51. A system according to claim 50, wherein the fluid treatment device comprises at least one additional port for introducing an additive into the composition.   52. The system according to claim 51, wherein the at least one additional port opens into a passage upstream of the nozzle outlet.   52. The system according to claim 51, wherein the at least one additional port opens into a passage immediately downstream of the nozzle outlet.   54. A system according to claim 52 or 53, further comprising an additional port near the second holding container.   Further, the apparatus includes a second fluid treatment device and a second retention vessel downstream of the first retention vessel, the second fluid treatment device having a second passage for receiving the composition from the first retention vessel. 49. The system according to claim 48, wherein the second transport fluid nozzle has a nozzle outlet opening into the second passage and has a throat portion having a cross-sectional area smaller than that of the outlet. And a second treatment line comprising a first treatment line comprising a first fluid treatment device and a first holding vessel, and a second treatment line for receiving a supply of the following (a ₁ ) composition: A second fluid treatment device having a passage, and a second transport fluid nozzle having a nozzle outlet opening into the second passage and having a throat portion having a cross-sectional area smaller than that of the outlet, and b ₁ ) a second holding vessel in fluid communication with the outlet of the second passage, wherein the first and second treatment lines include those connected in parallel between the composition supply and the fermentation vessel 49. A system according to claim 48.   The method further comprises a mixing vessel having an inlet and an outlet, wherein the mixing vessel is in fluid communication with the passage of the fluid treatment device at the inlet, and the mixing vessel mixes the supply of biomass and working fluid to form the composition. 48 system.   49. The system according to claim 48, further comprising a pump upstream of at least one processing unit.   49. The system according to claim 48, further comprising a plurality of fluid treatment devices connected in series and / or in parallel to form an array.   49. The system according to claim 48, further comprising a plurality of second fluid treatment devices connected in series and / or in parallel to each other to form an array.   51. The system according to claim 50, further comprising a temperature adjustment unit for raising the temperature of the composition between the first and / or second fluid treatment device and its respective first and / or second holding container. .   62. A system according to claim 61, wherein the temperature control unit is a steam generator.   58. The system according to claim 57, further comprising a distillation device downstream of the fermentation vessel.   64. A system according to claim 63, wherein the distillation device is downstream of the inlet of the mixing vessel.   65. The system according to claim 64, further comprising a first return line connecting the distillation device to the inlet of the fluid treatment device.   64. The system according to claim 63, further comprising a separation device downstream of the distillation device.   The system according to claim 64, further comprising a separation device downstream of the inlet of the mixing vessel.   68. The system according to claim 67, further comprising a second return line connecting the separation device to the inlet of the fluid treatment device.   68. A system according to any one of claims 66 and 67, wherein the separation device comprises a centrifuge.   57. The system according to claim 56, further comprising a transport fluid supply unit in fluid communication with the at least one transport fluid nozzle.   71. A system according to claim 70, wherein the transport fluid supply unit supplies transport fluid to both the first and second fluid treatment devices.   49. A system according to claim 48, wherein the transport fluid is steam.   49. Bioethanol produced according to the system of claim 48. A method for producing bioethanol from biomass comprising: (a) inducing at least a first portion of a composition comprising biomass and working fluid to flow into a passage of a fluid treatment device;
(B) injecting a high velocity transport fluid into the composition through a nozzle communicating with the passage of the fluid treatment device, whereby the transport fluid is subdivided into working fluid and the flow pattern of vapor and droplets downstream of the nozzle Applying a shear force to the composition so as to form,
(C) condensing vapor and droplet flow patterns;
(D) transferring the composition to a first holding container;
(E) holding the composition in a first holding container at a first predetermined temperature for a first predetermined time, wherein liquefying enzyme is added to the composition before or during the process;
(F) transferring the composition to a second holding container during a first predetermined time;
(G) holding the composition in a second holding container at a second predetermined temperature for a second predetermined time;
(H) cooling the composition to a predetermined fermentation temperature;
(I) adding a fermenting agent to the composition;
(J) transferring the composition to a fermentation vessel; and (k) producing the fermented composition comprising bioethanol for a predetermined fermentation time at a predetermined fermentation temperature in the fermentation vessel. Holding the method.

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