NZ612188B2 - A method of producing sugar from paper - Google Patents
A method of producing sugar from paper Download PDFInfo
- Publication number
- NZ612188B2 NZ612188B2 NZ612188A NZ61218812A NZ612188B2 NZ 612188 B2 NZ612188 B2 NZ 612188B2 NZ 612188 A NZ612188 A NZ 612188A NZ 61218812 A NZ61218812 A NZ 61218812A NZ 612188 B2 NZ612188 B2 NZ 612188B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- paper
- feedstock
- sugar
- ions
- mrad
- Prior art date
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Classifications
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M21/00—Bioreactors or fermenters specially adapted for specific uses
- C12M21/18—Apparatus specially designed for the use of free, immobilized or carrier-bound enzymes
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M27/00—Means for mixing, agitating or circulating fluids in the vessel
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
- C12M29/00—Means for introduction, extraction or recirculation of materials, e.g. pumps
- C12M29/06—Nozzles; Sprayers; Spargers; Diffusers
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P19/00—Preparation of compounds containing saccharide radicals
- C12P19/02—Monosaccharides
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P19/00—Preparation of compounds containing saccharide radicals
- C12P19/14—Preparation of compounds containing saccharide radicals produced by the action of a carbohydrase (EC 3.2.x), e.g. by alpha-amylase, e.g. by cellulase, hemicellulase
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P2201/00—Pretreatment of cellulosic or lignocellulosic material for subsequent enzymatic treatment or hydrolysis
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P2203/00—Fermentation products obtained from optionally pretreated or hydrolyzed cellulosic or lignocellulosic material as the carbon source
-
- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P7/00—Preparation of oxygen-containing organic compounds
- C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
- C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
- C12P7/06—Ethanol, i.e. non-beverage
- C12P7/08—Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate
- C12P7/10—Ethanol, i.e. non-beverage produced as by-product or from waste or cellulosic material substrate substrate containing cellulosic material
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
- C12P7/00—Preparation of oxygen-containing organic compounds
- C12P7/02—Preparation of oxygen-containing organic compounds containing a hydroxy group
- C12P7/04—Preparation of oxygen-containing organic compounds containing a hydroxy group acyclic
- C12P7/06—Ethanol, i.e. non-beverage
- C12P7/14—Multiple stages of fermentation; Multiple types of microorganisms or re-use of microorganisms
-
- C—CHEMISTRY; METALLURGY
- C13—SUGAR INDUSTRY
- C13K—SACCHARIDES OBTAINED FROM NATURAL SOURCES OR BY HYDROLYSIS OF NATURALLY OCCURRING DISACCHARIDES, OLIGOSACCHARIDES OR POLYSACCHARIDES
- C13K1/00—Glucose; Glucose-containing syrups
- C13K1/02—Glucose; Glucose-containing syrups obtained by saccharification of cellulosic materials
-
- C—CHEMISTRY; METALLURGY
- C13—SUGAR INDUSTRY
- C13K—SACCHARIDES OBTAINED FROM NATURAL SOURCES OR BY HYDROLYSIS OF NATURALLY OCCURRING DISACCHARIDES, OLIGOSACCHARIDES OR POLYSACCHARIDES
- C13K13/00—Sugars not otherwise provided for in this class
- C13K13/002—Xylose
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/10—Biofuels, e.g. bio-diesel
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
Abstract
The disclosure relates to a method of producing an alcohol product or intermediate, comprising: combining a slurry of paper with a saccharifying agent in a vessel, the paper having a filler content greater than about 10wt%; allowing at least a portion of the paper to saccharify producing sugar, while mixing the contents of the vessel with a jet mixer and fermenting at least a portion of the sugar with a microorganism, where the contents of the vessel comprise at least one shear sensitive ingredient and the jet mixer provides gentle mixing so as to minimize damage. le mixing the contents of the vessel with a jet mixer and fermenting at least a portion of the sugar with a microorganism, where the contents of the vessel comprise at least one shear sensitive ingredient and the jet mixer provides gentle mixing so as to minimize damage.
Description
A METHOD OF PRODUCING SUGAR FROM PAPER
BACKGROUND
Magazines, catalogs, and other paper products that contain high levels of
coatings, pigments, and inks, are widely available as waste materials. While efforts
are made to recycle this waste paper, generally by repulping it for use in recycled
paper products, it would be advantageous ifthis waste paper could be economically
utilized as a feedstock to make other types of products.
SUMMARY
Generally, this invention relates to methods ofprocessing paper oclcs,
and to intermediates and products made therefrom. In ular, the invention s
generally to the processing of certain types of relatively heavy paper feedstocks, such
as highly pigmented papers, and or loaded papers, such as paper that has been color
printed (printed with colors other than or in on to black), e.g., magazines, and
other papers.
Many ofthe methods disclosed herein e microorganisms or products
produced by microorganisms, e.g., enzymes, to cess the feedstock, producing
useful intermediates and products, e.g., energy, fuels, foods and other materials. For
e, in some cases enzymes are used to saccharify the feedstocks, converting the
feedstocks to sugars. The sugars may be used as an end product or intermediate, or
processed further, e.g., by fermentation. For example xylose can be hydrogenated to
xylitol and glucose can be hydrogenated to sorbitol.
In one aspect, the invention features methods for producing a sugar, e.g., in the
form of a solution or suspension, that includes providing a paper feedstock, the paper
feedstock ing offset printing paper e.g., offset printed paper, colored paper
and/0r coated paper e.g., polycoated paper and optionally mixing the feedstock with a
fluid and/or saccharifying agent.
Some implementations include one or more ofthe following features. The
paper feedstock may have a basis weight greater than 35 lb, e.g., from about 35 lb to
330 lb and/or the paper may have a high filler content, e.g., r than about 10
wt.% e. g., greater than 20 wt.%. For e, the filler or any coating can be an
nic material. The paper may also have a high grammage, e.g., greater than
about 500 g/m2. The paper may comprise a pigment or printing ink, e.g., at a level
greater than about 0.025 wt.%. The paper can have an ash content greater than about 8
wt.%.
The method can further include adding a microorganism, for example a yeast
and/or a bacteria (e.g., from the genus Clostridium), to the paper feedstock or
saccharified paper and producing a product or intermediate.
In one embodiment ofthe present invention there is provided a method of
ing a t or intermediate, the method comprising:_combining a slurry of
paper with a saccharifying agent in a vessel, the paper having a high filler t
greater than about 10wt%;_allowing at least a portion of the paper to saccharify,
ing a sugar, while mixing the contents ofthe vessel with a jet mixer; and
fermenting at least a portion of the sugar with a microorganism, wherein the ts
ofthe vessel comprise at least one shear sensitive ingredient and the jet mixer
provides gentle mixing so as to ze damage to the at least one shear sensitive
ingredient.
The product can be a fiJel, including, for example, alcohols (e.g., methanol,
ethanol, propanol, isopropanol, itol, nol, isobutanol, sec—butanol, tert-
butanol, ethylene glycol, propylene glycol, 1,4-butane diol and/or glycerin), sugar
alcohols (e.g., erythritol, glycol, glycerol, sorbitol threitol, arabitol, ribitol, mannitol,
dulcitol, fucitol, iditol, isomalt, maltitol, lactitol, xylitol and other polyols), organic
. acids (e.g., formic acid, acetic acid, propionic acid, c acid, valeric acid, caproic
acid, palmitic acid, stearic acid, oxalic acid, malonic acid, succinic acid, glutaric acid,
oleic acid, linoleic acid, glycolic acid, lactic acid and/or y—hydroxybutyric acid),
hydrocarbons (methane, ethane, propane, isobutene, pentane, n-hexane, sels
and/or bio—gasolines), hydrogen and mixtures of these.
The method can fmther include adding a ased nutrient source to the
mixture, e.g., a nutrient source selected from the group consisting of grains,
vegetables, residues of grains, residues of vegetables, and mixtures thereof, for
example wheat, oats, barley, soybeans, peas, legumes, potatoes, corn, rice bran, corn
meal, wheat bran, and mixtures thereof. In such cases, the mixture can finther include
an enzyme system selected to release nts from the ased nutrient source,
e.g., a system sing a protease and an amylase.
The method can include detoxifying the sugar solution or suspension. The
method can include further processing the sugar, for example, by separating xylose
and or
PCT/U82012/024970
glucose from the sugar. In some cases, the saccharification can be conducted at a pH of
about 3.8 to 4.2. The mixture can further e a nitrogen source.
In some cases, the method further includes physically ng the paper
feedstock, for example mechanically treating to reduce the bulk density of the paper
feedstock and/or se the BET surface area of the feedstock. Physically treating the
paper feedstock can include irradiation, for e, with an electron beam. The method
can e mixing the paper feedstock with a fluid. The method can include detOXifying
the paper feedstock, sugar, and/or other products or ediates. The paper feedstock
may be in the form of magazines. The paper feedstock may also be a laminate of at least
one layer of a r and paper and may further include at least one layer of a metal
e.g., aluminum.
gh many embodiments include the use of relatively heavy paper
feedstocks, e.g., containing fillers and/or coatings other papers can be used e.g.,
newsprint.
Unless ise defined, all technical and scientific terms used herein have the
same meaning as commonly understood by one of ordinary skill in the art to which this
invention belongs. Although methods and materials similar or equivalent to those
described herein can be used in the practice or testing of the present invention, suitable
methods and materials are described below. All publications, patent applications,
patents, and other references mentioned herein are incorporated by reference in their
entirety. In case of conflict, the present specification, including definitions, will control.
In addition, the materials, methods, and examples are illustrative only and not intended to
be limiting.
Other features and advantages of the invention will be apparent from the
following detailed description, and from the claims.
DESCRIPTION OF DRAWINGS
is a flow diagram illustrating sion of a feedstock to ethanol Via
production of a glucose solution.
is a tic diagram of an ethanol manufacturing facility.
is a diagram illustrating the enzymatic hydrolysis of cellulose to glucose.
PCT/U52012/024970
DETAILED DESCRIPTION
Using the methods and nutrient packages described herein, paper feedstocks that
include high levels of pigments, colors, fillers and/or coatings, and/or that have a high
basis , and the saccharified derivatives of such feedstocks, can be bioprocessed,
e.g., using fermentation, to produce useful intermediates and ts such as those
bed herein. In some cases, the feedstock includes high levels pigments and/or
fillers such as those feedstocks used in printing, e.g., nes. es of such
feedstocks are described herein. Feedstocks of this type are advantageous for a number
of reasons, including their relatively low cost (if waste materials are used) and, in the
case of high basis weight papers, their relatively high density, which contributes to ease
of handling and sing.
CONVERTING CELLULOSIC AND LIGNOCELLULOSIC
MATERIALS T0 ALCOHOLS
Referring to a process for manufacturing an alcohol, e.g., ethanol, or a
butanol e.g., isobutanol, sec—butanol, tert—butanol or n—bntanol, can inciude, for example,
optionally mechanically treating the feedstock (step 110), before and/or after this
ent, optionally treating the feedstock with another physical treatment, for example
ation, to further reduce its itrance (step 112), saccharifying the feedstock to
form a sugar solution (step 114), optionally transporting, e.g., by ne, railcar, truck
or barge, the solution (or the feedstock, enzyme and water, if saccharification is
performed en route) to a manufacturing plant (step 116), and then bio—processing the
treated feedstock to produce a desired product (step 118), which is then processed further,
e. g., by distillation (step 120). If d, lignin t can be measured (step 122) and
process parameters can be set or adjusted based on this measurement (step 124), as
described in U.S. Application Serial No 12/704,519, filed on February 11, 2010, the
complete disclosure ofwhich is incorporated herein by reference.
Because paper feedstocks are generally low in, or entirely tack, nutrients to
support bioprocesses, it is generally preferred that nutrients be added to the system, for
example in the form of a food—based nutrient source or nutrient package, as disclosed in
U.S. Application Serial No. 13/1 84,138, orated by reference herein in its entirety.
WO 12488 PCT/U82012/024970
When utilized, the food-based nutrient source or nutrient package is present during bio-
processing (step 118), e.g., tation, and may in some preferred implementations
also be t during the saccharification step (step 114). In some implementations, the
food-based nutrient source or nutrient package is added at the ing of step 114,
along with an enzyme ation suitable for saccharification, fermentation, and release
of nutrients from the food—based nutrient source.
Saccharification is conducted under a first set of process conditions (e.g.,
ature and pH), and then when saccharification has proceeded to a d extent
the process conditions may be adjusted (e.g., by ing pH from 4 to 5) to allow
‘10 fermentation to proceed.
In some cases the feedstock includes materials that are not beneficial to the
processing of the feedstock or decrease the quality ofthe intermediates and/or products.
For example there may be materials that are toxic, and/or solid inorganic materials or
insoluble organic materials. The toxic materials can be detrimental, for example, by
reducing the effectiveness of enzymes and/or rganisms. Examples of toxic
materials are pigments and inks described herein. Solid inorganic materials can be
detrimental, for example, in increasing the total viscosity and density of solutions in
various processes as well as forming slurries, sludge and settled material that may, for
example, block openings, be difficult to remove, e.g., from the bottom of tanks, and/or
increase the wear on . es of inorganic materials are fillers and coatings
described herein. Insoluble organic materials can, for example, contaminate the final fuel
products and/or cause foaming during mixing or other processing steps. Examples of
insoluble organic materials are polymers used in polycoated paper described herein. It
can therefore be advantageous to remove some of the insoluble solids and organic
materials and to detoxify the feedstock at any point during the processing as described
herein. Surprisingly, it has been found that in some cases materials in the feedstock that
would be expected to be detrimental, as discussed above, do not significantly ely
affect the s. For example, some yeasts that provide ethanol by fermentation of
sugars derived from paper ocks appear to be very resilient to various pigments, inks
and fillers.
W0 2012/112488 PCT/U52012/024970
The manufacturing plant used in steps 0 (and in some cases all of the steps
bed above) can be, for example, an existing starch—based or sugar-based l
plant or one that has been retrofitted by removing or decommissioning the equipment
upstream from the bio-processing system (which in a typical ethanol plant generally
includes grain receiving equipment, a hatmnermiil, a slurry mixer, cooking equipment
and liquefaction equipment). In some cases, the feedstock received by the plant can be
input directly into the fermentation equipment. A retrofitted plant is shown schematically
in and described below as well as, for e, in US. Serial No. 12/429,045,
filed Apiil 23, 2009, the complete disclosure ofwhich is incorporated herein by
'10 reference.
shows one particular system that utilizes the steps described above for
treating a feedstock and then using the treated feedstock in a fermentation process to
produce an alcohol. System 100 includes a module 102 in which a feedstock is initially
mechanically treated (step 12, above), a module 104 in which the mechanically d
feedstock is structurally modified (step 14, above), e.g., by irradiation, and a module 106 in
which the urally modified feedstock is subjected to further mechanical treatment (step
16, above). As discussed above, the module 106 may be ofthe same type as the module
102, or a different type. In some implementations the urally modified ock can be
returned to module 102 for further mechanical treatment rather than being further
mechanically treated in a separate module 106.
As described herein, many variations ofsystem 100 can be utilized.
After these treatments, which may be repeated as many times as required to obtain
desired feedstock properties, the treated feedstock is delivered to a fermentation system 108.
Mixing may be performed during tation, in which case the mixing is preferably
relativeiy gentle (low shear) so as to ze damage to shear sensitive ingredients such as
enzymes and other rganisms. In some embodiments, jet mixing is used, as described
inU.S. Serial No. 12/782,694, ,977 and 13/293,985, the complete disclosures of
which are incorporated herein by reference.
Referring again to fermentation es a crude ethanol mixture, which
flows into a holding tank 110. Water or other solvent, and other non-ethanol components,
are stripped from the crude ethanol mixture using a stripping column 112, and the ethanol is
PCT/U82012/024970
then distilled using a distillation unit 1 14, e.g., a rectifier. Distillation may be by vacuum
distillation. Finally, the l can be dried using a molecular sieve 116 and/or denatured,
ifnecessary, and output to a desired shipping .
In some cases, the systems described herein, or components thereof, may be
portable, so that the system can be orted (e.g., by rail, truck, or marine vessel) from
one location to another. The method steps described herein can be performed at one or
more locations, and in some cases one or more ofthe steps can be performed in transit.
Such mobile processing is described in US. Serial No. 12/374,549 and International
ation No. W0 2008/01 1598, the full sures ofwhich are incorporated herein
1O by reference.
Any or all of the method steps described herein can be med at ambient
temperature. If desired, cooling and/or heating may be ed during certain steps.
For example, the feedstock may be cooled during mechanical treatment to increase its
brittleness. In some embodiments, cooling is employed before, during or after the initial
mechanical ent and/or the subsequent mechanical treatment. Cooling may be
performed as bed in US. Serial No. 12/502,629, now US. Patent No. 7,900,857 the
full disclosure ofwhich is incorporated herein by reference. Moreover, the temperature
in the fermentation system 108 may be controlled to enhance saccharification and/or
fermentation.
The individual steps of the methods described above, as well as the materials used,
will now be described in further detail.
PHYSICAL ENT
Physical treatment processes can include one or more of any of those described
herein, such as mechanical treatment, chemical treatment, irradiation, sonication,
oxidation, pyrolysis or steam explosion. Treatment methods can be used in combinations
oftwo, three, four, or even all of these technologies (in any order). When more than one
treatment method is used, the methods can be applied at the same time or at different
times. Other processes that change a molecular structure of a feedstock may also be
used, alone or in combination with the processes disclosed herein.
PCT/U82012/024970
Mechanical Treatments
In some cases, methods can include mechanically treating the feedstock.
Mechanical treatments include, for example, cutting, milling, pressing, grinding, shearing
and chopping. Milling may include, for example, ball milling, hammer milling,
rotor/stator dry or wet g, freezer g, blade milling, knife milling, disk milling,
roller g or other types of milling. Other mechanical treatments e, e.g., stone
grinding, cracking, mechanical ripping or tearing, pin grinding or air attrition milling.
ical treatment can be advantageous for “opening up,H (Cstressing,”
ng and ring cellulosic or other materials in the feedstock, making the
cellulose of the als more susceptible to chain scission and/or reduction of
oiystallinity. The open materials can also be more tible to oxidation when
irradiated.
In some cases, the mechanical treatment may include an initial preparation of the
feedstock as received, e.g., size reduction of materials, such as by cutting, grinding,
shearing, pulverizing or chopping. For example, in some cases, loose feedstock (e. g.,
e Offset Paper and/0r Polycoated Paper) is prepared by ng or shredding.
Alternatively, or in addition, the feedstock material can first be physically treated
by one or more of the other physical treatment methods, cg, chemical treatment,
radiation, sonication, oxidation, pyrolysis or steam explosion, and then mechanically
treated. This sequence can be advantageous since materials treated by one or more of the
other treatments, e.g., irradiation or pyrolysis, tend to be more brittle and, therefore, it
may be easier to further change the molecular structure of the material by mechanical
treatment.
In some embodiments, mechanical treatment includes shearing to expose fibers of
the material. ng can be performed, for example, using a rotary knife cutter. Other
methods of ically treating the feedstock include, for example, milling or grinding.
Milling may be performed using, for example, a hammer mill, ball mill, colloid mill,
conical or cone mill, disk mill, edge mill, Wiley mill or grist mill. ng may be
performed using, for example, a stone grinder, pin grinder, coffee grinder, or burr
grinder. Grinding may be provided, for e, by a reciprocating pin or other element,
PCT/U82012/024970
as is the ease in a pin mill. Other mechanical treatment methods include mechanical
g or tearing, other methods that apply pressure to the material, and air attrition
milling. Suitable mechanical treatments further include any other technique that changes
the molecular ure ofthe feedstock.
If desired, the mechanically treated material can be passed through a screen, e.g.,
having an average opening size of 1.59 mm or less (1/16 inch, 0.0625 inch). In some
embodiments, shearing, or other mechanical ent, and screening are performed
' concurrently. For e,
a rotary knife cutter can be used to concurrently shear and
screen the feedstock. The feedstock is sheared between stationary blades and rotating
blades to provide a d material that passes through a screen, and is captured in a bin.
The paper feedstock can be mechanically treated in a d1y state (e.g., having little
or no free water on its surface), a hydrated state (e.g., having up to ten percent by weight
absorbed water), or in a wet state, e.g., having between about 10 percent and about 75
percent by weight water. The fiber Source can even be ically treated while
partially or fully submerged under a liquid, such as water, l or isopropanoi.
The feedstock can also be mechanically treated under a gas (such as a stream or
atmosphere of gas other than air), e.g., oxygen or nitrogen, or steam.
Mechanical ent systems can be configured to produce streams with specific
morphology characteristics such as, for example, surface area, porosity, bulk density, and
length-to-width ratio.
In some embodiments, a BET surface area of the mechanically treated material is
greater than 0.1 mz/g, e.g., greater than 0.25 m2/g, greater than 0.5 nil/g, greater than 1.0
mZ/g, greater than 1.5 mZ/g, greater than 1.75 m2/g, greater than 5.0 mZ/g, greater than 10
m2/g, greater than 25 mZ/g, greater than 35 mz/g, greater than , greater than 60
mZ/g, greater than 75 mZ/g, greater than 100 mz/g, greater than 150 m2/g, greater than 200
nag/g, or even greater than 250 mz/g.
In some situations, it can be desirable to prepare a low bulk density material,
densify the al (e.g., to make it easier and less costly to transport to another site),
and then reveit the material to a lower bulk y state. Densified materials can be
processed by any ofthe methods described herein, or any material processed by any of
the s described herein can be subsequently ed, e.g., as disclosed in U.S.
PCT/U52012/024970
Serial No. 12/429, 045 now US. Patent No. 7,932,065 and , the full
disclosures of which are incorporated herein by reference.
Radiation Treatment
One or more radiation processing ces can be used to process the paper
feedstock, and to provide a structurally d material which functions as input to
further processing steps and/or sequences. Irradiation can, for e, reduce the
molecular weight and/or crystallinity of feedstock. Radiation can also sterilize the
materials, or any media needed to bioprocess the material.
In some embodiments, the radiation may be provided by (1) heavy charged
particles, such as alpha particles or protons, (2) electrons, ed, for example, in beta
decay or electron beam accelerators, or (3) electromagnetic radiation, for e,
gamma rays, x rays, or ultraviolet rays. In one approach, radiation produced by
ctive substances can be used to irradiate the feedstock. In another approach,
electromagnetic radiation (e.g., ed using electron beam emitters) can be used to
irradiate the feedstock. In some embodiments, any combination in any order or
concurrently of (1) h (3) may be utilized. The doses applied depend on the desired
effect and the particular feedstock.
In some instances when chain scission is desirable and/or polymer chain
functionalization is desirable, particles r than electrons, such as protons, helium
nuclei, argon ions, silicon ions, neon ions, carbon ions, phosphorus ions, Oxygen ions or
nitrogen ions can be utilized. When ring-opening chain scission is desired, positively
charged particles can be utilized for their Lewis acid properties for enhanced ring—
opening chain scission. For example, when maximum oxidation is desired, oxygen ions
can be utilized, and when maximum nitration is desired, nitrogen ions can be utilized.
The use ofheavy les and positively charged particles is described in US. Serial No.
12/417,699, now US. Patent No. 7,931,784, the full disclosure ofwhich is incorporated
herein by nce.
In one method, a first al that is or includes cellulose having a first number
average lar weight (Mm) is irradiated, e.g., by treatment with ionizing radiation
(cg, in the form of gamma radiation, X—ray radiation, 100 nm to 280 nm ultraviolet (UV)
light, a beam of electrons or other charged les) to provide a second material that
includes cellulose having a second number e molecular weight (Mm) lower than
the first number e molecular weight. The second material (or the first and second
material) can be combined with a microorganism (with or without enzyme treatment) that
can utilize the second and/or first material or its constituent sugars or lig'nin to produce an
intermediate or product, such as those described herein.
Since the second material includes cellulose having a reduced molecular weight
relative to the first material, and in some instances, a reduced crystallinity as well, the
second material is generally more dispersible, swellable and/or soluble, e.g., in a on
containing a microorganism and/or an enzyme. These properties make the second
material easier to process and more susceptible to chemical, enzymatic and/or biological
attack relative to the first material, which can greatly improve the production rate and/or
production level of a desired product, e.g., ethanol.
In some embodiments, the second number average molecular weight (Mm) is
lower than the first number average molecular weight (Mm) by more than about 10
percent, e.g., more than about 15, 20, 25, 30, 35, 40, 50 percent, 60 percent, or even more
than about 75 t.
In some instances, the second material includes cellulose that has a crystallinity
(C2) that is lower than the crystallinity (C1) of the cellulose ofthe first material. For
example, (C2) can be lower than (C1) by more than about 10 percent, e.g., more than
about 15, 20, 25, 30, 35, 40, or even more than about 50 percent.
In some embodiments, the second al can have a level of oxidation (02) that
is higher than the level of oxidation (01) of the first material. A higher level of Oxidation
of the material can aid in its dispersability, swellability and/or solubility, further
enhancing the material’s susceptibility to chemical, enzymatic or biological attack. In
some embodiments, to increase the level of the ion of the second material relative
to the first material, the ation is performed under an oxidizing environment, e.g.,
under a t of air or oxygen, producing a second al that is more oxidized than
the first al. For example, the second material can have more hydroxyl groups,
aldehyde , ketone groups, ester groups or carboxylic acid groups, which can
increase its hydrophilieity.
WO 12488 PCT/U82012/024970
Ionizing Radiation
Each form of radiation ionizes the paper feedstock via particular interactions, as
determined by the energy of the radiation. Heavy charged particles primarily ionize
matter Via Coulomb scattering; furthermore, these interactions produce tic
electrons that may r ionize matter. Alpha particles are identical to the nucleus of a
helium atom and are produced by the alpha decay of various radioactive nuclei, such as
isotopes of bismuth, polonium, astatine, radon, francium, , l actinides, such
as actinium, m, uranium, neptunium, curium, californium, americium, and
plutonium.
When particles are ed, they can be neutral (uncharged), positively charged or
negatively charged. When charged, the charged particles can bear a single positive or
negative charge, or multiple charges, e.g., one, two, three or even four or more charges.
In instances in which chain scission is desired, positively charged particles may be
ble, in part due to their acidic nature. When particles are utilized, the particles can
have the mass of a resting electron, or greater, e.g., 500, 1000, l500, 2000, 10,000 or
even 100,000 times the mass of a resting electron. For example, the particles can have a
mass of from about 1 atomic unit to about 150 atomic units, e.g., from about 1 atomic
unit to about 50 atomic units, or from about 1 to about 25, e.g., l, 2, 3, 4, 5, 10, 12 or 15
amu. Accelerators used to accelerate the particles can be electrostatic DC,
electrodynarnic DC, RF linear, magnetic induction linear or continuous wave. For
example, ron type accelerators are available from IBA, m, such as the
Rhodotron® system, while DC type accelerators are available from RDI, now IBA
Industrial, such as the Dynamitron®. Ions and ion accelerators are discussed in
Introductory Nuclear s, Kenneth S. Krane, John Wiley & Sons, Inc. , Krsto
Prelec, FIZIKA B 6 (1997) 4, l77-—206, Chu, William T., “Overview of Light-Ion Beam
y” Columbus—Ohio, ICRU-IAEA Meeting, 18-20 March 2006,1wata, Y. et al.,
“Alternating—Phase-Focused IH—DTL for Heavy-Ion Medical Accelerators” Proceedings
ofEPAC 2006, Edinburgh, Scotland and Leaner, C.M. et al., “Status of the
Superconducting ECR Ion Source Venus” Proceedings ofEPAC 2000, Vienna, Austria.
Gamma radiation has the advantage of a significant penetration depth into a
variety of materials. s of gamma rays include radioactive nuclei, such as isotopes
PCTfU$2012/024970
of cobalt, calcium, technicium, chromium, gallium, indium, iodine, iron, krypton,
samarium, selenium, sodium, m, and xenon.
Sources ofx rays include electron beam collision with metal targets, such as
tungsten or molybdenum or alloys, or compact light sources, such as those produced
commercially by Lyncean.
s for ultraviolet radiation include deuterium or cadmium lamps.
Sources for infrared radiation include sapphire, zinc, or seienide window ceramic
lamps.
Sources for aves include klystrons, Slevin type RF sources, or atom beam
sources that employ hydrogen, oxygen, or nitrogen gases.
In some embodiments, a beam of electrons is used as the radiation . A
beam of electrons has the advantages of high dose rates (e.g., l, 5, or even 10 Mrad per
second), high hput, less containment, and less confinement equipment. Electrons
can also be more efficient at causing chain scission. In addition, electrons having
energies of 4—1 0 MeV can have a penetration depth of 5 to 30 mm or more, such as 40
Electron beams can be generated, e.g., by electrostatic generators, cascade
generators, transformer generators, low energy rators with a scanning , low
energy accelerators with a linear e, linear accelerators, and pulsed accelerators.
Electrons as an ionizing ion source can be useful, e.g., for relatively thin sections of
material, e.g., less than 0.5 inch, e.g., less than 0.4 inch, 0.3 inch, 0.2 inch, or less than
0.1 inch. In some embodiments, the energy of each electron of the electron beam is from
about 0.3 MeV to about 2.0 MeV (million electron volts), e.g., fi'om about 0.5 MeV to
about 1.5 MeV, or from about 0.7 MeV to about 1.25 MeV.
Electron beam irradiation devices may be procured commercially from Ion Beam
Applications, Louvain-la-Neuve, Belgium or the Titan Cmporation, San Diego, CA.
Typical electron energies can be 1 MeV, 2 MeV, 4.5 MeV, 7.5 MeV, or 10 MeV.
Typical on beam irradiation device power can be 1 kW, 5 kW, 10 kW, 20 kW, 50
kW, 100 kW, 250 kW, or 500 kW. The level of depolymerization ofthe feedstock
depends on the electron energy used and the dose applied, while exposure time s
on the power and dose. Typical doses may take values of 1 kGy, 5 kGy, 10 kGy, 20 kGy,
PCT/U52012/024970
50 chy, 100 kGy, or 200 kGy. In a some ments energies between 0 MeV
(e.g., 0.5—0.8 MeV, 0.5—5 MeV, 0.84 MeV, 0.8—3 MeV, 0.8-2 MeV or 5 MeV) can
be used. In some embodiment doses between 1—100 Mrad (e.g., 2-80 Mrad, 5-50 Mrad, 5-
40 Mrad, 5-30 Mrad or 5-20 Mrad) can be used. In some preferred embodiments, an
energy between 0.8~3 MeV (e.g., 0.8-2 MeV or 0.8—1.5 MeV) combined with doses
between 5-50 Mrad (cg, 5—40 Mrad, 5—30 Mrad or 5—20 Mrad) can be used.
Ion Particle Beams
Particles heavier than electrons can be utilized to irradiate paper feedstock
als. For example, protons, helium nuclei, argon ions, silicon ions, neon ions carbon
ions, phosphorus ions, oxygen ions or nitrogen ions can be utilized. In some
embodiments, particles heavier than ons can induce higher amounts of chain
scission (relative to lighter particles). In some instances, vely charged particles can
induce higher amounts of chain scission than negatively charged particles due to their
acidity.
Heavier particle beams can be generated, e.g., using linear accelerators or
rons. In some embodiments, the energy of each particle of the beam is from about
1.0 MeV/atomic unit (MeV/emu) to about 6,000 MeV/atomic unit, e.g., from about 3
MeV/ atomic unit to about 4,800 MeV/atomic unit, or from about 10 MeV/atomic unit to
about 1,000 MeV/atomic unit.
In certain embodiments, ion beams used to irradiate paper feedstock can include
more than one type of ion. For e, ion beams can include mixtures of two or more
(e. g., three, four or more) different types of ions. Exemplary mixtures can include carbon
ions and protons, carbon ions and oxygen ions, nitrogen ions and protons, and iron ions
and protons. More generally, mixtures of any ofthe ions discussed above (or any other
ions) can be used to form irradiating ion beams. In particular, mixtures of relatively light
and relatively heavier ions can be used in a single ion beam.
In some embodiments, ion beams for irradiating paper ock include
positively-charged ions. The positively charged ions can include, for example, positively
charged hydrogen ions (cg, protons), noble gas ions (e.g., , neon, argon), carbon
ions, nitrogen. ions, oxygen ions, silicon atoms, phosphorus ions, and metal ions such as
PCT/U52012/024970
sodium ions, calcium ions, and/or iron ions. Without wishing to be bound by any theory,
it is believed that such positively-charged ions behave ally as Lewis acid moieties
when exposed to materials, initiating and sustaining cationic ring-opening chain scission
reactions in an oxidative nment.
In certain embodiments, ion beams for irradiating paper feedstock include
negatively—charged ions. Negatively charged ions can include, for example, negatively
charged hydrogen ions (e.g., hydride ions), and negatively d ions of various
relatively electronegative nuclei (cg, oxygen ions, nitrogen ions, carbon ions, n
ions, and phosphorus ions). Without wishing to be bound by any theory, it is believed
that such negatively-charged ions behave chemically as Lewis base moieties when
exposed to materials, causing anionic ring—opening chain scission reactions in a reducing
nment.
In some embodiments, beams for irradiating paper feedstock can include neutral
atoms. For example, any one or more of hydrogen atoms, helium atoms, carbon atoms,
nitrogen atoms, oxygen atoms, neon atoms, silicon atoms, phosphorus atoms, argon
atoms, and iron atoms can be included in beams that are used for irradiation. In general,
mixtures of any two or more of the above types of atoms (e. g., three or more, four or
more, or even more) can be present in the beams.
In certain embodiments, ion beams used to irradiate paper feedstock include
singly—charged ions such as one or more of H“, H', He+, Ne+, Ari", C)”, C", 0+, 0", N, N,
Si", Si', 13+, P", Na+, Ca+, and Fe”. In some embodiments, ion beams can e
ly—charged ions such as one or more of C”, C“, C”, NEH", NSJ", N3“, 02+, 02', 022‘,
Si2+, Si“, Si ', and Si“'. In general, the ion beams can also include more complex
polynuclear ions that bear multiple positive or negative charges. In n embodiments,
by virtue of the structure of the clear ion, the positive or negative charges can be
effectively distributed over substantially the entire structure ofthe ions. In some
embodiments, the positive or negative charges can be somewhat localized over ns
ofthe structure of the ions.
PCT/U82012/024970
Electromagnetic ion
In ments in which the irradiating is performed with electromagnetic
radiation, the electromagnetic radiation can have, e.g., energy per photon (in electron
volts) of r than 102 eV, e.g., greater than 103, 104, 105, 106, or even greater than 107
eV. In some embodiments, the electromagnetic radiation has energy per photon of
between 104 and 107, e.g., between 105 and 106 eV. The electromagnetic radiation can
have a ncy of, e.g., greater than 1016 hz, greater than 1017 hz, 1018, 1019, 1020, or
even greater than 1021 hz. Typical doses may take values of greater than 1 Mrad (e.g.,
greater than 1 Mrad, greater than 2 Mrad). In some embodiments, the omagnetic
1O radiation has a frequency ofbetween 1018 and 1022 hz, e.g., between 1019 to 1021 hz. In
some embodiment doses between 1-100 Mrad (e.g., 2—80 Mrad, 5-50 Mrad, 5-40 Mrad,
-30 Mrad or 5—20 Mrad) can be used.
Quenching and Controlled Functionalization
After treatment with ionizing radiation, any ofthe als or mixtures described
herein may become ionized; that is, the treated material may include radicals at levels
that are detectable with an electron spin resonance spectrometer. If an ionized feedstock
remains in the atmosphere, it will be ed, such as to an extent that carboxylic acid
groups are generated by reacting with the atmospheric oxygen. In some instances with
some materials, such oxidation is desired e it can aid in the further breakdown in
molecular weight of the carbohydrate—containing biomass, and the oxidation groups, e.g.,
carb0xylic acid groups can be helpful for solubility and microorganism utilization in
some instances. However, since the radicals can “live” for some time after irradiation,
e.g., longer than 1 day, 5 days, 30 days, 3 months, 6 months or even longer than 1 year,
material properties can continue to change over time, which in some ces, can be
undesirable. Thus, it may be desirable to quench the ionized material.
After ionization, any ionized material can be quenched to reduce the level of
radicals in the ionized material, e.g., such that the radicals are no longer detectable with
the electron spin reSOnance spectrometer. For example, the radicals can be quenched by
the ation of a sufficient pressure to the material and/or by utilizing a fluid in contact
with the ionized al, such as a gas or liquid, that reacts with (quenches) the radicals.
PCT/U82012/024970
Using a gas or liquid to at least aid in the quenching of the radicals can be used to
functionalize the ionized material with a desired amount and kind of functional groups,
such as carboxylic acid groups, enol groups, aldehyde groups, nitro groups, nitrile
groups, amino , allryl amino groups, alkyl groups, chloroalkyl groups or
chlorofluoroalkyl groups.
In some instances, such quenching can improve the stability of some of the
ionized materials For example, quenching can improve the resistance of the material to
oxidation. Functionalization by quenching can also improve the solubility of any
material described herein, can improve its thermal stability, and can improve al
utilization by various microorganisms. For example, the functional groups imparted to
the material by the quenching can act as receptor sites for attachment by microorganisms,
c.g., to enhance ose ysis by various microorganisms.
In some embodiments, quenching includes an application of pressure to the
ionized material, such as by mechanically deforming the material, e.g., directly
ically compressing the al in one, two, or three dimensions, or applying
re to a fluid in which the material is immersed, e.g., isostatic pressing. In such
instances, the ation of the material itself brings radicals, which are often trapped in
crystalline s, in close enough proximity so that the radicals can recombine, or
react with another group. In some instances, the pressure is applied together with the
ation of heat, such as a ent ty ofheat to elevate the temperature of the
material to above a melting point or softening point of a component of the material, such
ose or another polymer. Heat can improve molecular mobility in the al,
which can aid in the quenching of the radicals. When pressure is utilized to quench, the
pressure can be greater than about 1000 psi, such as greater than about 1250 psi, 1450
psi, 3625 psi, 5075 psi, 7250 psi, 10000 psi or even greater than 15000 psi.
In some embodiments, quenching includes contacting the ionized material with a
fluid, such as a liquid or gas, e.g., a gas capable of ng with the radicals, such as
acetylene or a mixture of acetylene in nitrogen, ethylene, chlorinated ethylenes or
chlorofluoroethylenes, propylene or mixtures of these gases. In other particular
embodiments, quenching includes contacting the ionized material with a liquid, e.g., a
liquid soluble in, or at least capable of penetrating into the material and reacting with the
PCT/U52012/024970
radicals, such as a diene, such as 1,5—eyclooctadiene. In some specific embodiments,
quenching includes contacting the material with an antioxidant, such as Vitamin E. If
desired, the feedstock can include an antioxidant dispersed therein, and the quenching can
come from contacting the antioxidant dispersed in the feedstock with the radicals.
Functionalization can be ed by utilizing heavy charged ions, such as any of
the heavier ions described herein. For example, if it is desired to enhance oxidation,
charged oxygen ions can be utilized for the irradiation. If nitrogen functional groups are
d, nitrogen ions or anions that e nitrogen can be utilized. Likewise, if sulfur
or phosphorus groups are desired, sulfur or phosphorus ions can be used in the
1O irradiation.
Doses
In some instances, the irradiation is performed at a dosage rate of greater than
about 0.25 Mrad per , e.g., greater than about 0.5, 0.75, 1.0, 1.5, 2.0, or even
greater than about 2.5 Mrad per second. In some embodiments, the irradiating is
performed at a dose rate of between 5.0 and 1500.0 kilorads/hour, e.g., between 10.0 and
750.0 kiiorads/hour or between 50.0 and 350.0 kilorads/hour. In some embodiments,
ation is performed at a dose rate of greater than about 0.25 Mrad per second, e.g.,
greater than about 0.5, 0.75, 1, 1.5, 2, 5, 7, 10, 12, 15, or even greater than about 20 Mrad
per second, e.g., about 0.25 to 2 Mrad per second.
In some embodiments, the ating (with any radiation source or a combination
of sources) is performed untii the material receives a dose of 0.25 Mrad, e.g., at least 1.0,
2.5, 5.0, 8.0, 10, 15, 20, 25, 30, 35, 40, 50, or even at least 100 Mrad. In some
embodiments, the ating is performed until the material receives a dose of between
1.0 Mrad and 6.0 Mrad, e.g., n 1.5 Mrad and 4.0 Mrad, 2 Mrad and 10 Mrad, 5
Mrad and 20 Mrad, 10 Mrad and 30 Mrad, 10 Mrad and 40 Mrad, or 20 Mrad and 50
Mrad. In some embodiments, the irradiating is performed until the material receives a
dose of from about 0.1 Mrad to about 500 Mrad, fi'orn about 0.5 Mrad to about 200 Mrad,
from about 1 Mrad to about 100 Mrad, or from about 5 Mrad to about 60 Mrad. In some
ments, a relatively low dose of radiation is applied, e.g., less than 60 Mrad.
2012/024970
Sonication can reduce the lar weight and/or crystallinity of the polymers
comprising the paper feedstock, e.g., cellulose. Sonication can also be used to sterilize
the materials. As discussed above with regard to radiation, the process parameters used
for sonication can be varied depending on various factors.
In one method, a first material that includes cellulose having a first number
average molecular weight (Mm) is dispersed in a medium, such as water, and ted
and/or otherwise cavitated, to provide a second material that includes ose having a
second number average molecular weight (Mm) lower than the first number average
molecular weight. The second material (or the first and second al in n
embodiments) can be combined with a microorganism (with or without enzyme
treatment) that can utilize the second and/or first material to produce an intermediate or
product.
Since the second material includes cellulose having a reduced molecular weight
relative to the first material, and in some instances, a reduced crystallinity as well, the
second material is generally more sible, swellable, and/or soluble, e.g., in a solution
containing a microorganism.
In some embodiments, the second number average molecular weight (Mm) is
lower than the first number average molecular weight (Mm) by more than about 10
percent, e.g., more than about 15, 20, 25, 30, 35, 40, 50 percent, 60 percent, or even more
than about 75 percent.
In some instances, the second material es cellulose that has a crystallinity
(C2) that is lower than the crystallinity (C1) of the cellulose of the first material. For
e, (C2) can be lower than (C1) by more than about 10 percent, e.g., more than
about 15, 20, 25, 30, 35, 40, or even more than about 50 t.
In some embodiments, the sonication medium is an s medium. If desired,
the medium can include an oxidant, such as a peroxide (e.g., hydrogen peroxide), a
dispersing agent and/or a buffer. Examples of dispersing agents include ionic dispersing
agents, e.g., sodium lauryl sulfate, and non-ionic dispersing agents, e.g., poly(ethylene
glycol).
PCT/U32012/024970
In other embodiments, the sonication medium is non—aqueous. For example, the
sonication can be med in a hydrocarbon, e.g., toluene or heptane, an ether, e.g.,
diethyl ether or tetrahydrofuran, or even in a liquefied gas such as argon, xenon, or
nitrogen.
flrolysis
One or more pyrolysis processing sequences can be used to process paper
feedstock from a wide variety of different s to extract useful nces from the
materials, and to provide partially degraded materials which function as input to further
1O processing steps and/or sequences. Pyrolysis can also be used to ize the materials.
Pyrolysis conditions can be varied depending on the characteristics of the feedstock
and/or other factors.
In one example, a first material that includes cellulose having a first number
average molecular weight (Mm) is pyrolyzed, e.g., by heating the first material in a tube
furnace (in the presence or e of oxygen), to provide a second material that includes
cellulose having a second number average molecular weight (Mm) lower than the first
number average lar .
Since the second material includes cellulose having a reduced molecular weight
relative to the first al, and in some instances, a reduced crystallinity as well, the
second material is generally more dispersible, swellablc and/or soluble, e.g., in a on
containing a microorganism.
In some embodiments, the second number average molecular weight (Mm) is
lower than the first number average molecular weight (Mm) by more than about 10
percent, e.g., more than about 15, 20, 25, 30, 35, 40, 50 percent, 60 percent, or even more
than about 75 percent.
In some instances, the second material includes cellulose that has a crystallinity
(C2) that is lower than the llinity (C1) ofthe cellulose ofthe first material. For
example, (C2) can be lower than (C1) by more than about 10 percent, e. g., more than
about 15, 20, 25, 30, 35, 40, or even more than about 50 percent.
PCT/U52012/024970
In some embodiments, the pyrolysis ofthe materials is continuous. In other
ments, the material is pyrolyzed for a pre-determined time, and then allowed to
cool for a second pie-determined time before pyrolyzing again.
Oxidation
One or more oxidative processing sequences can be used to process paper
ck from a wide variety of different sources to extract useful substances from the
feedstock, and to provide partially degraded and/or altered feedstock which functions as
input to fiirther processing steps and/or sequences. The oxidation conditions can be
varied, e.g., depending on the lignin content of the feedstock, with a higher degree of
oxidation generally being desired for higher lignin content feedstocks.
In one method, a first al that es ose having a first number
average molecular weight (Mm) and having a first oxygen content (01) is oxidized, e.g.,
by heating the first al in a stream of air or oxygen-enriched air, to provide a second
material that includes cellulose having a second number average molecular weight (Mm)
and having a second oxygen t (02) higher than the first oxygen content (01).
The second number average molecular weight of the second material is generally
lower than the first number average lar weight of the first material. For example,
the molecular weight may be reduced to the same extent as discussed above with respect
to the other physical treatments. The llinity ofthe second material may also be
reduced to the same extent as discussed above with respect to the other physical
treatments.
In some embodiments, the second oxygen content is at least about five percent
higher than the first oxygen content, e.g., 7 .5 percent higher, 10.0 t higher, 12.5
percent higher, 15.0 percent higher or 17.5 percent higher. In some preferred
embodiments, the second oxygen content is at least about 20.0 percent higher than the
first oxygen content ofthe first material. Oxygen content is measured by elemental
analysis by pyrolyzing a sample in a furnace operating at 1300 °C or higher. A suitable
elemental analyzer is the LEGO 32 analyzer with a VTF-900 high temperature
pyrolysis furnace.
PCT/U52012/024970
Generally, oxidation of a al occurs in an oxidizing environment. For
example, the oxidation can be ed or aided by pyrolysis in an oxidizing environment,
such as in air or argon enriched in air. To aid in the oxidation, various chemical agents,
such as oxidants, acids or bases can be added to the material prior to or during oxidation.
For example, a peroxide (e.g., benzoyl peroxide) can be added prior to oxidation.
Some oxidative methods ofreducing recalcitrance in a paper feedstock employ
Fenton-type chemistry. Such methods are disclosed, for example, in US. Serial No.
,289, the complete disclosure of which is incorporated herein by reference.
ary oxidants include peroxides, such as hydrogen per0xide and l
peroxide, persulfates, such as ammonium persulfate, activated forms of oxygen, such as
ozone, permanganates, such as potassium permanganate, perchlorates, such as sodium
perchlorate, and hypochlorites, such as sodium hypochlorite (household bleach).
In some situations, pH is maintained at or below about 5.5 during contact, such as
between 1 and 5, between 2 and 5, n 2.5 and 5 or between about 3 and 5.
Oxidation conditions can also include a contact period ofbetween 2 and 12 hours, e.g.,
between 4 and 10 hours or between 5 and 8 hours. In some instances, temperature is
ined at or below 300 °C, e.g., at or below 250, 200, 150, 100 or 50 °C. In some
instances, the temperature remains substantially t, e.g., at or about 20—25 °C.
In some embodiments, the one or more oxidants are d as a gas, such as by
generating ozone in-sz'tu by irradiating the al through air with a beam of particles,
such as electrons.
In some embodiments, the mixture further es one or more hydroquinones,
such as 2,5-dimethoxyhydroquinone (DMI-IQ) and/or one or more benzoquinones, such
as 2,5-dimethoxy—l,4-benzoquinone (DMBQ), which can aid in electron transfer
reactions.
In some embodiments, the one or more oxidants are electrochemically—generated
in—sz‘tu. For example, hydrogen peroxide and/0r ozone can be electro—chemically
produced within a contact or reaction vessel.
WO 12488 PCT/U82012/024970
Other ses To Solubilize, Reduce Reealeitrance Or To Funetionalize
Any ofthe processes of this aph can be used alone without any of the
processes described herein, or in combination with any of the processes described herein
(in any order): steam explosion, chemical treatment (e.g., acid treatment (including
concentrated and dilute acid treatment with mineral acids, such as sulfuric acid,
hydrochloric acid and organic acids, such as trifluoroaeetic acid) and/or base ent
(e.g., treatment with lime or sodium hydroxide)), UV treatment, screw ion
treatment (see, e.g., U.S. Serial No. 13/099,151, solvent treatment (e.g., treatment with
ionic liquids) and freeze milling (see, e.g., U.S. Serial No. 12/502,629 now US. Patent
No. 7,900,857).
Saccharification
In order to convert the paper feedstock to fermentable sugars, the cellulose in the
feedstock is hydrolyzed by a saccharifying agent, e.g., an enzyme, a process referred to as
saccharification. The materials that include the cellulose are treated with the enzyme,
e.g., by combining the material and the enzyme in a solvent, e.g., in an s solution.
Enzymes and organisms that break down cellulose contain or manufacture various
cellulolytic s (cellulases), ligninascs or various small molecule biomassdestroying
metabolites. These enzymes may be a compiex of enzymes that act
synergistically to degrade crystalline cellulose. es of ccllulolytic enzymes
include: endoglucanases, cellobiohydrolases, and cellobiases (B—glucosidases). Referring
to a ccllulosic substrate is initially hydrolyzed by endoglucanases at random
locations producing oligomeric intermediates. These intermediates are then ates for
exo—splitting ases such as cellobiohydrolase to produce cellobiose from the ends of
the cellulose polymer. Cellobiose is a water-soluble nked dimer of glucose. Finally
ccllobiasc cleaves cellobiose to yield glucose.
Suitable saccharifying agents are bed, for example, in the Materials section
below.
As noted above, a food—based nutrient source or nutrient package is preferably
added prior to or during saccharification, and an enzyme is added that is selected to
WO 12488 PCT/USZOl2/024970
e nts from the food-based nutrient source. Suitable enzymes are described,
for example, in the Materials section below.
The saccharifrcation process can be partially or completely med in a tank
(e.g., a tank having a volume of at least 4000, 40,000, 400,000 L or 1,000,000 L) in a
manufacturing plant, and/or can be partially or completely performed in transit, e.g., in a
rail car, tanker truck, or in a supertanker or the hold of a ship. The time required for
complete saccharification will depend on the process conditions and the feedstock and
enzyme used. If saccharification is performed in a manufacturing plant under controlled
conditions, the cellulose may be substantially entirely converted to glucose in about 12—
96 hours. If rification is performed partially or completely in transit,
saccharification may take longer.
It is generally preferred that the tank contents be mixed during saccharification,
e.g., using jet mixing as bed in US. Applications Serial Nos. 12/782,694,
13/293,985 and ,977, the full disclosure ofwhich are incorporated by reference
herein.
The addition of surfactants can enhance the rate of saccharification. Examples of
surfactants include non—ionic surfactants, such as a Tween® 20 or Tween® 80
polyethylene glycol surfactants, ionic surfactants, or amphoteric surfactants.
It is generally preferred that the concentration ofthe resulting glucose solution be
relatively high, e.g., greater than 40%, or greater than 50, 60, 70, 80, 90 or even greater
than 95% by weight. This reduces the volume to be shipped, if saccharification and
fermentation are med at different locations, and also inhibits microbial growth in
the solution. However, lower concentrations may be used, in which case it may be
ble to add an antimicrobial additive, e.g., a broad spectrum otic, in a low
concentration, e.g., 50 to 150 ppm. Other le antibiotics include amphotericni B,
ampicillin, chlorarnphenicol, ciprofloxacin, gentamicin, hygromycin B, kanamycin,
neomycin, penicillin, puromycin, streptomycin. Antibiotics will inhibit growth of
microorganisms during transport and storage, and can be used at appropriate
concentrations, e.g., between 15 and 1000 ppm by weight, e.g., between 25 and 500 ppm,
or between 50 and 150 ppm. If d, an antibiotic can be included even if the sugar
concentration is relatively high.
PCT/U52012/024970
A relatively high concentration solution can be obtained by limiting the amount of
water added to the feedstock with the enzyme. The concentration can be lled, e.g.,
by controlling how much saccharification takes place. For example, concentration can be
increased by adding more ock to the solution. In order to keep the sugar that is
being produced in solution, a surfactant can be added, e.g., one ofthose sed above.
Solubility can also be increased by increasing the temperature of the solution. For
example, the solution can be ined at a temperature of 40—50°C, 60-80°C, or even
higher.
In some embodiments, the feedstock is processed to convert it to a convenient and
concentrated solid material, e.g., in a powdered, granulate or particulate form. The
concentrated material can be in a purified, or a raw or crude form. The concentrated form
can have, for example, a total sugar concentration ofbetween about 90 t by weight
and about 100 percent by weight, e.g., 92, 94, 96 or 98 t by weight sugar. Such a
form can be particularly cost effective to ship, e.g., to a bioprocessing facility, such as a
biofuel manufacturing plant. Such a form can also be advantageous to store and ,
easier to manufacture and becomes both an intermediate and a product, providing an
option to the biorefinery as to which products to manufacture.
In some instances, the powdered, granulate or ulate material can also
include one or more of the materials, e.g., additives or chemicals, described , such
as the food—based nutrient or nt package, a nitrogen source, e. g., urea, a surfactant,
an enzyme, or any microorganism described herein. In some instances, all materials
needed for a bio-process are combined in the powdered, granulate or particulate material.
Such a form can be a particularly convenient form for transporting to a remote
cessing facility, such as a remote biofuels manufacturing facility. Such a form can
also be advantageous to store and handle.
In some instances, the powdered, granulatc or ulate material (with or
Without added materials, such as additives and chemicals) can be treated by any of the
physical treatments described in US. Serial No. 12/429,045, incorporated by reference
above. For e, ating the powdered, granulate or particulate material can
increase its solubility and can sterilize the material so that a bioprocessing facility can
WO 12488 PCT/U52012/024970
integrate the material into their process directly as may be required for a contemplated
ediate or product.
In certain ces, the powdered, granulate or particulate material (with or
without added materials, such as additives and chemicals) can be carried in a ure or
a carrier for ease of transport, storage or handling. For example, the structure 01' carrier
can include or incorporate a bag or liner, such as a degradable bag or liner. Such a form
can be ularly useful for adding directly to a cess system.
Fermentation
‘10 Microorganisms can produce a number of useful intermediates and products by
fermenting a low molecular weight sugar produced by saccharifying the paper feedstock
materials. For example, fermentation or other bioprocesses can produce alcohols, organic
acids, hydrocarbons, hydrogen, proteins or mixtures of any of these materials.
Yeast and Zymomonas ia, for example, can be used for fermentation or
conversion. Other microorganisms are discussed in the Materials section, below. The
optimum pH for fermentations is about pH 4 to 7. For example, the optimum pH for yeast
is from about pH 4 to 5, while the optimum pH for Zymomonas is from about pH 5 to 6.
Typical fermentation times are about 24 to 168 hours (cg, 24 to 96 hrs) with
temperatures in the range of 20 °C to 40 °C (e.g., 26 °C to 40 °C), however philic
microorganisms prefer higher temperatures.
In some embodiments e.g., when anaerobic organisms are used, at least a portion
of the fermentation is conducted in the absence of oxygen e.g., under a blanket of an inert
gas such as N2, Ar, He, C02 or mixtures thereof. Additionally, the mixture may have a
constant purge of an inert gas flowing through the tank during part of or all of the
fermentation. In some cases, anaerobic condition can be achieved or maintained by
carbon dioxide production during the fermentation and no additional inert gas is needed.
In some embodiments, all or a n of the fermentation process can be
interrupted before the low molecular weight sugar is completely ted to a t
(cg, ethanol). The intermediate fermentation products include high concentrations of
Sugar and carbohydrates. The sugars and carbohydrates can be isolated as discussed
below. These ediate fermentation products can be used in preparation of food for
PCT/U82012/024970
human or animal consumption. Additionally or alternatively, the intermediate
fermentation products can be ground to a fine particle size in a stainless—steel laboratory
mill to produce a flour—like substance.
The fermentations include the methods and products that are disclosed in US.
Provisional Application Serial No. ,559, filed December 22, 2012, and U.S.
application 61/579,576, filed December 22, 2012 incorporated by nce herein in its
Mobile fermentors can be utilized, as described in US. Provisional Patent
Application Serial 60/832,735, now Published International Application No. WO
2008/011598. Similarly, the sacchariiication equipment can be mobile. Further,
saccharification and/or fermentation may be performed in part or entirely during transit.
Distillation
After fermentation, the resulting fluids can be distilled using, for example, a “beer
column” to te ethanol and other alcohols from the majority of water and residual
solids. The vapor g the beer column can be, c.g., 35% by weight ethanol and can be
fed to a rectification column. A e of nearly azeotropic (92.5%) ethanol and water
from the rectification column can be purified to pure (99.5%) ethanol using vapor-phase
molecular sieves. The beer column bottoms can be sent to the first effect of a effect
evaporator. The ication column reflux ser can provide heat for this first
effect. After the first effect, solids can be separated using a centrifuge and dried in a
rotary dryer. A portion (25%) of the centrifuge effluent can be recycled to fermentation
and the rest sent to the second and third evaporator effects. Most of the evaporator
condensate can be returned to the process as fairly clean condensate with a small portion
split offto waste water treatment to prevent build-up of low—boiling compounds.
Other Possible Processing of Sugars
Processing during or after saccharifieation can include isolation and/or
concentration of sugars by chromatography e.g., simulated moving bed chromatography,
precipitation, fugation, crystallization, solvent evaporation and combinations
thereof. In on, or optionally, processing can include isomerization of one or more of
PCT/U82012/024970
the sugars in the sugar solution or suspension. Additionally, or ally, the sugar
solution or suspension can be chemically sed e.g., glucose and xylose can be
hydrogenated to sorbitol and xylitol respectively. Hydrogenation can be accomplished by
use of a catalyst e.g., Pt/y—Alzog, Ru/C, Raney Nickel in ation with H2 under high
pressure e.g., 10 to 12000 psi.
Some le processing steps are sed in in US. Provisional Application
Serial No. 61/579,552, filed December 22, 2012, and in US. Provisional Application
Serial No. 61/5 79,576 filed December 22, 2012, incorporated by reference herein in its
entirety above.
REMOVING 0F FILLERS, INKS, AND COATINGS
Paper feedstock used in the processes described can contain fillers, gs,
laminated material, pigments, inks and binders. These can be rem0ved and either
discarded or recycled as described here.
Inorganic fillers and coatings e. g., those described in the materials section below
can be d at any point during the process. For example, the inorganic filler and
coating can be removed from the ock after a mechanical, physical or chemical
treatment to reduce the recalcitrance of the feedstock; after ation with a fluid;
afier, during or before iification; after, during or before a purification step; after,
during or before a fermentation step; and/or after, during or before a chemical conversion
step. The fillers and coatings can be removed by any means e.g., by sedimentation,
precipitation, ligand sequestration, filtration, ion, chemical conversion and
centrifugation. Some of the physical treatments discussed herein (see Physical Treatment
section) can aid in separating the cellulosic mateiials from the inorganic fillers and
coatings (e. g., mechanical treatments, chemical treatments, irradiation, pyrolysis,
sonication and/or oxidiation). The recovered inorganic fillers can be recycled or
discarded.
Inks that are present can be removed from the feedstock at any point during the
process. Inks can be a complex medium composed of several components e.g., solvents,
pigments, dyes, resins, lubricants, solubilizers, surfactants, particulate matter and/or
fluorescers. For e, printed papers, e.g., magazines and catalogs, may include high
levels of the pigments generally used in printing inks. In some cases the papers include
metal—based ts, organic pigments, and/or Lake pigments. For example, pigments
that can be used are Yellow Lakes, Tartrazine Yellow Lake, Hansa Yellows, Diarylide'
s, Yellow azo pigments, Fluorescent Yellow, Diarylide Orange, DNA Orange,
Pyrazolone , Fast Orange FZG, Benzimidazolone Orange HL, Ethyl Lake Red C,
Para Reds, ine Red, Carmine F.B., Naphthol Reds and Rubines, Permanent Red
PRC, Bordeaux FRR, Rubine Reds, Lithol Reds, BON Red, Lithol Rubine 4B, BON
Maroon, Rhodamine 6G, Lake Red C, BON Aiylamide Red, Quinacrinone Magentas,
Copper Ferrocyanide Pink, Benzimidazolone es and Reds, Azo Magenta G,
Anthraquinone Scarlet, Madder Lakes, Phthalocyanine Blues, PMTA Victoria Blue,
Victoria Blue CFA, Ultramarine Blue, Indanthrene Blue, Alkali Blues, k Blue,
Benzimz‘dazolone Bordeaux HF 3R, PMTA Rhodarnine, PMTA Violet, Dioxazine Violet,
Carbazole Violet, Crystal Violet, ine Violet B, Thioindigoid Red, Phthalocyanine
, PMTA Greens, Benzirnidazolone Brown HFR, Cadmium Red, Cadmium
Yellow, Cadmium Oranges, m—Mercury Reds, Iron Oxide Yellows, Irons Oxide
Blues, Iron Oxide browns, Iron Oxide Reds, Ultramarine Blues, Ultramarine Violet,
Chromium Antimony Titanium Buff, copper phthalocyanine blue, green copper
phthalocyanine pigments, potash blue and soda blue pigments. The removal of ink may
help improve certain parts in the process. For example, some ink can be toxic to
microorganisms used in the process. The inks can also impart an undesirable coloration
or toxicity to the final product. Furthermore, ng the inks may allow these to be
recycled, improving the cost benefits to the process and lessening the environmental
impact of the paper feedstock. The inks can be removed by any means. For example,
removal may include sion, floatation, ng and/or washing steps, extraction
with solvents (e. g., supercritical C02, alcohol, water and organic solvents), settling,
al means, sieving and/or precipitation. Some of the physical treatments discussed
herein (see Physical Treatment section) can aid in separating the cellulosic materials from
the inks (e.g., mechanical treatments, chemical treatments, irradiation, pyrolysis,
sonication and/or oxidiation). In addition enzymatic deinking technologies such as those
disclosed in US. patent 224 hereby incorporated by reference herein, can be used.
PCT/U82012/024970
Coating materials, e.g., those found in poly-coated paper described in the
materials section below, can be d from the feedstock at any point during the
process. This can be done by, for example, the s mentioned above for removal of
pigments and inks and inorganic materials. In some cases, where polycoated paper is a
laminate, de—lamination can be done by, for example, chemical and/or mechanical means.
The non~cellulosic laminate portions can then be ted from the cellulose containing
layers and discarded and/or ed.
INTERMEDIATES AND TS
The processes and nts discussed herein can be used to convert paper feedstocks to
one or more products, Such as energy, fuels, foods and materials. Specific examples of
products include, but are not d to, hydrogen, sugars (e.g., glucose, xylose,
arabinose, mannose, galactose, fructose, disaccharides, oligosaccharides and
polysaccharides), alcohols (cg, monohydric alcohols or ic alcohols, such as
ethanol, n-propanol, isobutanol, sec—butanol, tert—butanol or n-butano l), hydrated or
hydrous alcohols, e.g., containing greater than 10%, 20%, 30% or even greater than 40%
water, sugars, biodiesel, c acids (e.g., acetic acid and/or lactic acid), hydrocarbons,
e.g., methane, , propane, isobutene, e, n—hexane, biodiesel, bio-gasoline and
mixtures thereof, co-products (e.g., proteins, such as cellulolytic proteins (enzymes) or
single cell proteins), and mixtures of any ofthese in any combination or relative
concentration, and optionally in combination with any additives, e.g., fiiel additives.
Other examples include carboxylic acids, such as acetic acid or butyric acid, salts of a
ylic acid, a mixture of carboxylic acids and salts of carboxylic acids and esters of
carboxylic acids (e.g., methyl, ethyl and n—propyl esters), ketones, aldehydes, alpha, beta
unsaturated acids, such as acrylic acid and olefins, such as ethylene. Other alcohols and
alcohol derivatives include propanol, propylene glycol, 1,4-butanediol, 1,3-propanediol,
sugar alcohols (e.g., crythritol, glycol, ol, sorbitol threitol, arabitol, ribitol,
mannitol, dulcitol, fucitol, iditol, isomalt, maltitol, lactitol, xylitol and other polyols),
methyl or ethyl esters of any of these alcohols. Other products e methyl te
and methylrnethacrylate. The product may also be an organic acid, e.g., lactic acid,
formic acid, acetic acid, propionic acid, butyric acid, succinic acid, valeric acid, caproic,
PCT/U82012/024970
palmitic acid, stearic acid, oxalic acid, e acid, glutaric acid, oleic acid, linoleic
acid, glycolic acid, 'y—hydroxybutyric acid, a mixture thereof, a salt of any of these acids,
or a mixture of any of the acids and their respective salts.
Other intermediates and products, including food and ceutical products,
are described in US. Serial No. ,900, the full disclosure of which is hereby
incorporated by nce herein.
Paper Feedstocks
Suitable paper feedstocks include paper that is highly pigmented, coated or filled
and can have a low calorific value. Sources of such paper include magazines, catalogs,
books, manuals, labels, calendars, greeting cards and other high quality printed materials
such as prospectuses, brochures and the like. The papers may include at least 0.025% by
weight ofpigment, filler or coating, e.g., from 0 to 80%, 0 to 50%, 0.1 to 50%, 0.1 to
%, 0.1 to 20%, 0.5 to 2.5%, 0.2 to 15%, 0.3 to 10%, 0.5 to 5%.
Other le paper feedstocks include high basis weight coated. paper and/or
paper with a high filler content i.e., at least 10 wt.%. These papers can be printed or
unprinted. Examples of this type of feedstock include paper having a basis weight, as
defined as the weight in pounds (lb) for a ream (500 ) of 25” X 38” sheets, of at
least 35 1b., for example at least 45 1b., at least 50 1b., at least 60 lb, at least 70 lb. or at
least 80 lb. The feedstock includes paper having a basis weight below 330 1b., for
example below about 300 lb, below about 250 lb, below about 200 1b, below about 150
1b, below about 120 lb, below about 110 1b, below about 105 lb or below about 100 lb.
For example the basis weight may be between 35 lb and 330 lb, 35 lb and 120 lb,
n 35 lb and 110 lb, between 35 lb and 100 lb, between 35 lb and 90 lb, between 45
lb and 120 lb, between 45 lb and 110 lb, between 45 lb and 100 lb, between 45 lb and 90
lb, between 50 lb and 120 lb, between 50 lb and 110 lb, between 50 lb and 100 lb,
between 50 lb and 90 1b, between 60 lb and 120 lb, between 60 lb and 110 lb, between 60
lb and 100 lb, between 60 lb and 90 1b, between 60 lb and 120 1b, between 60 lb and 110
lb, between 60 lb and 100 lb, between 60 lb and 90 lb, n 70 1b and 1201b, between
70 lb and 110 lb, between 70 lb and 100 lb, between 70 lb and 90 lb, between 90 lb and
PCTfUS2012/024970
330 lb, between 90 lb and 300 lb, between 90 1b and 250 lb, between 90 lb and 200 lb,
between 90 lb and 150 lb, between 90 lb and 110 1b, between 110 lb and 330 11), between
110 lb and 300 lb, between 110 lb and 250 lb, between 110 lb and 200 lb, between 110 lb
and 150 lb, between 130 lb and 330 lb, between 130 lb and 300 lb, between 130 lb and
250 lb, between 130 lb and 200 lb, or between 130 lb and 150 lb, In some embodiments,
the papers have relatively high density, e.g., greater than 1.11 g/cm3, in some cases from
about 1.11 to 2 g/crn3 e.g., 1.11 to 1.8 g/cm2, 1.11 to 1.6 g/cm2, 1.11 to 1.52 g/cm2, 1.2 to
1.8 g/cm2, 1.2 to 1.6 g/emz, 1.2 to 1.52 g/cm2, 1.3 to 1.8 g/cm2, 1.3 to 1,6 g/crn2 or 1.3 to
1.52 g/cm2 Such papers often have a high ash content e.g., at least 8wt.%, at least 10
wt.%, at least 15 wt.% at least 20 wt.% or at least 50 wt.%. The ash content can be
between 8 and 50%, e.g., between 10 and 50%, between 20 and 50%, between 30 and
50%, between 10 and 40%, between 20 and 40%, between 10 and 30% or between 10
and 20%. The papers can have a high filler content, e.g., at 0% by , e.g., at
least 20 wt%, at least 30 wt%, at least 40 wt% or at least 50 wt%. Filler contents can be
between 10 and 80%, e.g., between 20 and 80%, between 30 and 80%, between 40 and
80%, between 10 and 70%, between 20 and 70%, n 30 and 70%, between 40 and
70%, between 10 and 60%, between 20 and 60%, between 30 and 60% and n 40
and 60%. Suitable fillers include clays, oxides (e.g., titania, silica, alumina), carbonates
(e.g., m carbonate), tes (e.g., Talc) and aluminosilicates (e.g., Kaolin). One
suitable grade of coated paper is referred to in the industry as Machine Finished Coated
(MFC) paper. In other ments the paper can have a high surface density (i.e.,
Grammage), for example, at least 50 g/m2, at least 60 g/m2, at least 70 g/m2, at least 80
g/m2 or at least 90 g/m2.The Grammage can be between 50 g/m2 and 200 g/m2, between
50 g/rn2 and 175 g/m2, between 50 g/m2 and 150 g/m2, between 50 g/rn2 and 125 g/m2,
between 50 g/m2 and 100 g/m2, between 60 g/m2 and 200 g/m2, between 60 g/m2 and 175
g/m2, between 60 g/m2 and 150 g/m2, between 60 g/m2 and 125 g/m2, between 60 g/m2
and 100 g/m2, between 70 g/m2 and 200 g/m2, between 70 g/m2 and 175 g/m2, between
70 g/m2 and 150 g/m2, between 70 g/m2 and 125 g/m2, between 70 g/rn2 and 100 g/m2,
between 80 g/m2 and 200 g/m2, n 80 g/m2 and 175 g/m2, between 80 g/m2 and 150
g/ml, between 80 gi’m2 and 125 g/m2, between 80 g/m2 and 100 g/m2, between 130 g/m2
and 500 g/m2, between 130 g/m2 and 450 g/m2, between 130 g/m2 and 350 g/m2, between
130 g/m2 and 300 g/m2, between 130 g/m2 and 250 g/m2, between 130 g/m2 and 200
g/m2, between 130 g/m2 and 175 g/m2, between 130 g/m2 and 150 g/m2, between 200
g/m2 and 500 g/m2, between 200 g/m2 and 450 g/m2, between 200 g/m2 and 350 g/m2,
between 200 g/m2 and 300 g/m2, between 200 g/m2 and 250 g/m2, between 250 g/m2 and
500 g/m2, between 250 g/m2 and 450 g/ml, between 250 g/m2 and 350 g/m2, between 250
g/m2 and 300 g/m2, between 200 g/m2 and 250 g/m2, between 300 g/m2 and 500 g/m2,
between 300 g/m2 and 450 g/m2, or between 300 g/m2 and 350 g/m2.
Coated papers are well known in the paper art, and are disclosed, for example, in
US. Patent Nos. 6,777,075; 6,783,804, and 441, the full disclosures of which are
incorporated herein by reference.
Coated papers suitable as feedstock can include paper coated with an inorganic
material, for e the same materials used as fillers can be used in coatings.
onally, coated papers can include paper coated with a polymer coated paper).
Such paper can be made, for example, by extrusion g, brush coating, Curtain
coating, blade coating, air knife coating, cast coating or roller coating paper. For
example, sources ofsuch poly—coated paper include a variety of food containers,
including juice s, condiment s (e.g., sugar, salt, pepper), plates, pet food
bags, cups, bowls, trays and boxes for frozen foods. The poly-coated paper can, in
addition to paper, contain, for example, polymers, (e.g., polyethylene, polypropylene,
biodegradable polymers, silicone), latexes, binders, wax, and, in some cases, one or more
layers of aluminum. The poly coated papers can be multi layered laminate, for example,
made with one or more, e.g., two, three, four, five or more, layers of polyethylene and
paper and one or more, e.g., two, three or more layers of aluminum.
The paper feedstocks typically have a low gross calorie value e.g., below 7500
Btu/lb e.g, below 7400 Btu/lb, below 7200 Btu/lb, below 7000 Btu/lb, below 6800 ,
beiow 6600 Btu/lb, below 6400 Btu/lb, below 6200 Btu/lb, below 6000 Btu/lb, below
5800 Btu/lb, below 5600 Btu/lb, below 5400 Btu/lb or below 5200 Btu/lb. The gross
calorific value can be between about 5200 and 7500 Btu/lb e.g., between 6800 and 7000
Btu/1b, n 6700 and 7100 Btu/lb, between 6400 and 7100 Btu/lb, between 6600 and
6800 Btu/lb, between 6100 and 6700 Btu/lb, between 6100 and 6300 Btu/lb, between
6000 and 6350 Btu/lb, between 5600 and 6400 Btu/lb or n 5200 and 5500 Btu/lb.
PCT/U82012/024970
The gross calorific value can be measure using a bomb meter e. g., as outlined in
ASTM method E71 1.
The paper feedstock can have a basis weight between 35 1b and 330 lb, e.g. 45 lb
and 330 lb, 60 and 330 lb, 80 and 330 lb, 60 and 200 lb, 60 and 100 lb; optionally a filler
content greater than about 10 wt.%, e.g., between 10 and 80 wt.%, between 20 and 80
wt.%, between 30 and 80 wt.%, between 30 and 70 wt.%, between 230 and 60 wt.%;
optionally a grammage between 50 and 500 g/m2, e.g., 70 and 500 g/m2, 90 and 500 g/m2,
90 and 400 g/m2, 90 and 300 g/m2, 90 and 200 g/m2; and optionally a calorific value
between 7500 and 4000 Btu/lb, e.g., 7000 and 4000 Btu/lb, 6500 and 4000 , 5000
and 4000 Btu/lb, 6000 and 4500 Btu/lb; optionally an ash t between 8 and 50
wt.%, e.g., 10 and 80 wt.%, 10 and 60 wt.%, 10 and 50 wt.%, 20 and 50 wt.%.
Some suitable paper feedstock can include a homogeneous sheet formed by
irregularly intertwining cellulose fibers. These can include, for example, Abrasive Papers,
Absorbent Paper, Acid Free Paper, Acid ProofPaper, t Book Paper, Adhesive
Paper, Air Dried Paper, Air Filter Paper, Album Paper, Albumin Paper, Alkaline Paper,
Alligator Imitation Paper, Aluminum Foil Laminated paper, Ammunition Paper,
Announcement Card Paper, Anti Rust Paper, Anti—Tarnish Paper, Antique Paper,
Archival Paper, Art Paper, Asphalt Laminated Paper, Azurelaid Paper, Back Liner Paper,
Bacon Paper, Bagasse Paper, Bakers‘ Wrap, Balloon Paper, Banknote or Currency Paper,
Barograph Paper, Barrier Paper, Baiyta Paper, Beedi Wrap Paper, Bible Paper, Black
WaterproofPaper, Blade Wrapping Paper, Bloodproof Paper or r Paper, Blotting
Paper, Blueprint Paper, Board, Bogus Paper, Bond Paper, Book Paper, Boxboard, e
Printing Paper, Bread Wrapping Paper, Bristol Board, Business Form Paper, Butter
Wrapping Paper, Burnt Paper, Cable Paper, Calf Paper, Calico Paper, Candy Twisting
Tissue, Canvas Paper, less Paper, ard, Corrugated Cardboard, Carton
board, Cartridge paper, Cast Coated Paper, Catalogue Paper, Chart Paper, Check Paper,
Cheese Wrapping Paper, Chipboard, Chromo, Coarse Paper (also Industrial Paper),
Coated freesheet, Coated Paper, Coated White Top Liner, Cockle Finish Paper, Color—
fast papers, Commodity Paper, Colored Kraft, Condenser Tissue, Construction Paper,
nerboard, Copier Paper or Laser Paper, Correspondence Papers, Corrugated Board,
Corrugated Medium or Fluting Media or Media,Cotton Paper or Rag Paper, Cover Paper
PCT/U82012/024970
or Cover Stock, Creamwove Paper, Cut Sheet, Damask Paper, Decalcomania Paper,
Diazo Base Paper, Document Paper, Drawing Paper, Duplex Board, Duplex Paper, End—
leaf Paper, Envelop Paper, Esparto Paper, Extensible Kraft, Extrusion Coated Board, Fax
Base Paper,Flarne Resistant, d Paper, Fluorescent Paper, Folding Boxboard, Form
Bond, Freesheet, Fruit Wrapping Paper, Gasket Board, Glassine Paper, Glazed Paper,
Granite Paper, Gravure Paper, Gray Board, Greaseproof Paper, Green Paper,
Groundwood Papers, Gummed Paper, Gypsum Board, Handmade Paper, Hanging Paper,
Hard Sized Paper, Heat Seal Paper, Heat er Paper, Hi—Fi (High Finish) Paper,
Industrial Papers, Insect Resistant, Insulating Board, Ivory Board, Japan Paper, Jute
1O Paper, Kraft Bag Paper, Kraft liner, Kraft Paper, Kraft Waterproof Paper, Kraft ng
Paper, Label Paper, Lace Paper, Laid Paper, Laminated Paper, Laminated Linerboard,
Latex Paper, Ledger Paper, Lightproof Paper, Liner, Linerboard, Litmus Paper, On
Machine Coated, Magazine Paper, Manila, Map Paper, Marble Paper, Matrix Paper, Matt
ed Paper, Mechanical Paper, Mellow Paper, Metalization Base Paper, Machine
Finished Paper, Machine glazed Paper, Millboard, Mulberry Paper, Natural Colored
Papers or Self Colored , Newsprint, Oatmeal Paper, Offset Paper, Packaging
Paper, Paperboard, Pattern Paper, Permanent Paper, Photographic Paper, Playing Card
Stock, Pleading Paper, Poly Extrusion Paper, Postcard Board, Post—Consumer Waste
Paper, Poster Paper, Pre—Consumer Waste Paper, Pressure Sensitive Coated Paper,
Publishing Paper, Pulp Board, Release Paper, Roofing Paper, Safety Paper, Security
paper, Self Adhesive Paper, Self Contained Paper, Silicon Treated Paper, Single Faced
ated Board, Sized Paper, Stamp Paper, Strawboard, Suede Paper, Supercalendered
Paper, Surface-Sized, Super Art Paper, Synthetic Fiber Paper, Tag Paper, ner, Text
Paper, Thermal Paper, Translucent Drawing Paper, Transparent Paper, Treated Paper,
Union Kraft, Unglazed Paper, Un-sized Paper, Vaporproof Paper, Varnish—Label Paper,
Vegetable Parchment, Vellum Paper, Velour Paper, Velvet Finish Paper, Vulcanizing
Paper, Wadding, Wall Paper, Water—Color Paper, Water Finished Paper, Water ant
Paper, Waterleaf, Waxed Paper, Wet Strength Paper, White Top Liner, Willesden Paper,
Wipes or Wiper, Wove, Wrapper, Writing Paper and Xerographic Paper.
The feedstocks described herein can be used in combination with any of the
biomass feedstocks described in US. Application Serial No. 12/417,880, filed April 3,
2009, incorporated by reference herein in its entirety.
Saccharifying Agents
Suitable enzymes include cellobiases and cellulases capable of degrading
biomass.
Suitable cellobiases include a cellobiase from Aspergillus niger sold under the
tradename NOVOZYME 188W.
ases are capable of ing biomass, and may be of fimgal or bacterial
origin. Suitable s include cellulases from the genera Bacillus, Pseudomonas,
Humicola, Fusarium, Thielavia, Acremonz'zmz, Chin/sosporz‘um and Trichoderma, and
include species of Humicala, Coprz'nus, Thielavia, ‘um, Myceliophthora,
Acremom‘um, Cephalospommz, Scytalz‘dz'um, llium or Aspergillus (see, e.g., EP
458162), especially those produced by a strain selected from the species Humz’cola
insolens ssified as Scytalz‘dium philum, see, e.g., US. Patent No. 4,435,307),
Coprz'nus cinereus, 'zmz oxysporum, fifircelz'ophthora themzophila, Merz'pilus
giganteus, Thielavia terrestris, Acremom‘um sp., Acremonium persicinum, Acremonz‘um
m'um, nium brachypenium, m‘um dichromospomm, Acremom'um
obclavatum, Acremonium pinkertonz’ae, Acremom’um roseogrz'seum, Acremom’um
incoloratum, and Acremom’zmzfirratzmz; preferably from the species Hzmzz'cola insolens
DSM 1800, Fusarz'um oxysporum DSM 2672, ophz‘hora thermophila CBS 117.65,
Cephalosporium sp. RYM—202, nium Sp. CBS 478.94, Acremom'um Sp. CBS
265.95, Acremonium persicinum CBS 169.65, Acremonizmz acremonium AHU 9519,
Cephalosporium Sp. CBS 535.71, Acremonium brachypenium CBS 866.73, Acremom'zmr
dichromosporum CBS 683.73, Acremoniwn obclavatum CBS 311.74, m'um
pinkertom'ae CBS 157.70, Acremoniunz roseogrz'seum CBS 134.56, Acremom'um
incoloratum CBS , and Acremoniumfuratum CBS 299.7011. Cellulolytic enzymes
may also be obtained from Chms’osporz'zmz, preferably a strain of Chrysosporz'um
Iucknowense. Additionally, Trichodemza (particularly Trichoderma viride, Trichoderma
reesei, and Trichoderma kom'ngz'z'), alkalophilic us (see, for example, US. Patent
No. 3,844,890 and EP 458162), and Streptomyces (see, e.g., RP 458162) may be used.
PCT/U82012/024970
Enzyme complexes may be utilized, such as those available from Genencm®
under the tradename ACCELLERASE®, for example, Accellerase® 1500 enzyme
complex. Accellerase 1500 enzyme complex contains multiple enzyme activities, mainly
exoglucanase, endoglucanase (2200~2800 CMC U/g), ellulase, and beta-
glucosidase 75 pNPG U/g), and has a pH of 4.6 to 5.0. The endoglucanase activity
of the enzyme x is expressed in carboxymethylcellulose activity units (CMC U),
while the beta-glucosidase activity is reported in pNP—glucoside ty units (pNPG U).
In one embodiment, a blend of Accellerase® 1500 enzyme complex and METM
188 cellobiase is used.
Fermentation Agents
The microorganism(s) used in fermentation can be natural microorganisms and/or
engineered microorganisms. For example, the microorganism can be a bacterium, e.g., a
olytic bacterium, a fungus, e.g., a yeast, a plant or a protist, e.g., an algae, a
protozoa or a fungus-like t, e.g., a slime mold. When the organisms are compatible,
mixtures of organisms can be utilized.
Suitable fermenting microorganisms have the ability to convert carbohydrates,
such as glucose, fi'uctose, xylose, arabinose, mannose, gaiactose, oligosaccharides or
polysaccharides into fermentation products. Fermenting microorganisms include strains
of the genus Sacchromyces spp. e.g., Sacchromyces cerevz'sz'ae (baker’s ,
Saccharomyces distaticus, Saccharomyces uvarum; the genus Klzgiveromyces, cg,
species Kluyveromyces marxiamls, romycesfi'agilz's; the genus Candida, e.g.,
Candida pseudotropz'calz's, and Candida brassicae, Pichia stipitis (a relative of Candida
Shehatae, the genus Clavispora, e.g., species Clavispora lusz‘tam'ae and Clavz'spora
'ae, the genus Pachysolen, e.g., species Pachysolen tannophz‘lus, the genus
Bretannomyces, e.g., species Bretannomyces clausem‘i (Philippidis, G. P., 1996,
ose bioconversion technology, in Handbook on Biocthanol: Production and
Utilization, Wyman, C.E., ed., Taylor & Francis, Washington, DC, 179—212). Other
suitable microorganisms include, for example, Zymomonas lz's, Clostrz'dz'um
thermocellmn (Philippidis, 1996, supra), Clostridz'um saccharobutylacetonicum,
idium saccharobutylicun-z, Clostridium Pum'ceum, Clostridium beijernckii,
Clostridz'um acetobutylicmn, Moniliella is, Yarrowia Zz'polytica, Aureobasidz‘um sp.,
Trichosporonoides sp., Trigonopsis variabilis, Trichosporon sp., Moniliellaacetoabutans,
Typhula variabilis, Candida iae, gz'nomycetes, Pseudozyma aensz's,
yeast species of genera Zygosaccharomyces, Debazyomyces, Hansenula and Pichz'a, and
fiingi of the dematioid genus Torula.
Commercially available yeasts include, for example, Red Sta1®/Lesaffre Ethanol
Red able from Red Star/Lesaffre, USA), FALI® (available from Fleischmann’s
Yeast, a division of Burns Philip Food Inc., USA), SUPERSTART® (available from
Alltech, now Lalemand), GERT STRAND® (available from Gert Strand AB, Sweden)
and FERMOL® (available from DSM Specialties).
Nutrient e Ingredients
As discussed above, it may be preferred to include a nutrient package in the
system during saccharification and/or fermentation. Preferred nt packages contain
a food-based nutrient source, a nitrogen source, and in some cases other ingredients, e.g.,
phosphates. Suitable food-based nutrient s e grains and vegetables,
including those discussed above and many others. The food—based nutrient source may
include mixtures of two or more grains and/or vegetables. Such nutrient sources and
packages are disclosed in U.S. Application Serial No. 13/184,138, incorporated by
reference herein in its entirety above.
Enzymes for Releasing nts
When a food—based nutrient source is utilized, it is preferred that the saccharification
and/or fermentation mixture further include an enzyme system selected to release
nutrients, e.g., en, amino acids, and fats, from the food-based nutrient source. For
example, the enzyme system may e one or more enzymes selected from the group
consisting of amylases, pretenses, and mixtures thereof. Such systems are disclosed in
U.S. Application Serial No. 13/184,138, incorporated by reference herein in its entirety.
Fuel Cells
Where the methods described herein produce a sugar solution or suspension, this solution
or suspension can uently be used in a fuel cell. For example, fuel cells utilizing
sugars derived from cellulosic or lignocellulosic materials are disclosed in US.
Provisional Application Serial No. 61/579,568, filed December 22, 2011, the
complete disclosure of which is incorporated herein by reference.
Throughout the specification and claims, unless the t es otherwise,
the word ise” or variations such as “comprises” or “comprising”, will be
understood to imply the inclusion of a stated integer or group of integers but not the
exclusion of any other r or group of integers.
Each document, reference, patent application or patent cited in this text is
expressly incorporated herein in their entirety by reference, which means that it
should be read and considered by the reader as part ofthis text. That the document,
reference, patent application or patent cited in this text is not repeated in this text is
merely for reasons of conciseness.
Reference to cited material or information contained in the text should not be
understood as a concession that the material or information was part of the common
l5 general knowledge or was known in Australia or any other country.
OTHER MENTS
A number of embodiments of the invention have been described. Nevertheless,
it Will be understood that various modifications may be made without departing from
the spirit and scope of the invention.
For e, while it is possible to perform all the processes described herein
at one physical location, in some embodiments, the processes are ted at
multiple sites, and/or may be performed during transport.
Accordingly, other embodiments are within the scope of the following claims.
Claims (21)
1. A method of producing a product or intermediate, the method comprising: combining a slurry ofpaper with a rifying agent in a vessel, the paper having a high filler content greater than about 10wt%; allowing at least a portion of the paper to saccharify, producing a sugar, While mixing the contents of the vessel with a jet mixer; and fermenting at least a portion ofthe sugar with a rganism, wherein the contents of the vessel comprise at least one shear sensitive ingredient and the jet mixer provides gentle mixing so as to minimize damage to the at least one shear sensitive ingredient.
2. The method of claim 1, wherein the filler content is at least 20wt.%.
3. The method of claim 1 or 2, wherein the paper has an ash content of at least 8 wt.%.
4. The method of any ofthe above claims, wherein the paper r comprises a printing ink.
5. The method of any of the above claims, wherein the paper is in the form of magazines.
6. The method of any ofthe above claims, further comprising adding a food—based nutrient source to the mixture.
7. The method of claim 6, wherein the food—based nutrient source is selected from the group consisting of grains, vegetables, es of grains, residues of vegetables, and mixtures thereof.
8. The method of any of the above claims, wherein the product comprises a fuel selected from the group consisting of hydrogen, alcohols, organic acids, hydrocarbons, and mixtures thereof.
9. The method of any ofthe above claims, wherein the microorganism comprises a yeast and/or a ia.
10. The method of any of the above claims, further comprising physically treating the paper prior to the combining step.
11. The method of any of the above claims, further comprising processing the sugar.
12. The method of claim 12, wherein sing comprises separating xylose and/or glucose from the sugar.
13. The method of any of the above claims, n saccharification is conducted at a pH of about 3.8 to 4.2.
14. The method of claim 11, wherein the physically treating step comprises mechanically treating the paper to reduce the bulk density of the paper and/or increase the BET surface area of the paper.
15. The method of claim 6, wherein the food-based nutrient source is ed from the group consisting of wheat, oats, barley, soybeans, peas, s, potatoes, corn, rice bran, corn meal, Wheat bran, and mixtures thereof.
16. The method of any of the above , wherein the paper has a basis weight of at least 35 lb.
17. The method of_any of the above claims, wherein the paper has a basis weight between 35 lb and 330 lb.
18. The method of any one of the above claims, wherein the paper has an ash content of at least 8 wt.%.
19. The method of any one of claims 5-9, wherein the paper further comprises a printing ink.
20. The method of any one of the above claims, wherein the paper is in the form of magazines.
21. The method ing to claim 1 substantially as herein before described with reference to the Examples.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ709188A NZ709188A (en) | 2011-02-14 | 2012-02-14 | A method of production sugar from paper |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161442710P | 2011-02-14 | 2011-02-14 | |
US61/442,710 | 2011-02-14 | ||
PCT/US2012/024970 WO2012112488A2 (en) | 2011-02-14 | 2012-02-14 | Processing paper feedstocks |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ612188A NZ612188A (en) | 2015-07-31 |
NZ612188B2 true NZ612188B2 (en) | 2015-11-03 |
Family
ID=
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