WO2013013126A1 - Procédé et système pour produire un produit de fermentation utilisant un fermenteur à base conique - Google Patents

Procédé et système pour produire un produit de fermentation utilisant un fermenteur à base conique Download PDF

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Publication number
WO2013013126A1
WO2013013126A1 PCT/US2012/047546 US2012047546W WO2013013126A1 WO 2013013126 A1 WO2013013126 A1 WO 2013013126A1 US 2012047546 W US2012047546 W US 2012047546W WO 2013013126 A1 WO2013013126 A1 WO 2013013126A1
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WIPO (PCT)
Prior art keywords
fermenter
degrees
microorganism
cone
biomass
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Application number
PCT/US2012/047546
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English (en)
Inventor
Alan Belcher
Keith FARNSWORTH
Donald Dimasi
John ELLERSICK
Steven LICHT
M.S. Sivasubramanian
Ritchie KING
Yulin LU
Mohammed Moniruzzaman
William KENEALY
John Hannon
Michael Ladisch
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Mascoma Corporation
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Application filed by Mascoma Corporation filed Critical Mascoma Corporation
Priority to CA2842116A priority Critical patent/CA2842116A1/fr
Publication of WO2013013126A1 publication Critical patent/WO2013013126A1/fr

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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
    • C12M23/00—Constructional details, e.g. recesses, hinges
    • C12M23/02—Form or structure of the vessel
    • 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
    • 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

Definitions

  • the present invention is directed to processes and systems for producing a fermentation product using a cone-bottom fermenter.
  • the invention relates to an improved method of fermenting biomass in which a vessel configuration and a specialized microorganism are combined to obtain a controlled fermentation which reduces the need for costly physical agitation or mixing in the fermenter, for the production of fermentation products such as ethanol.
  • Useful fermentation products other than ethanol can also be produced.
  • Ethanol, and other products can be produced from a wide variety of lignocellulosic biomass feedstocks including agricultural plant wastes (e.g., corn stover, cereal straws, sugarcane, and sugarcane bagasse), plant wastes from industrial processes (e.g., sawdust, paper pulp), and consumer waste and energy crops grown specifically for fuel production, such as switchgrass.
  • Plant wastes e.g., corn stover, cereal straws, sugarcane, and sugarcane bagasse
  • plant wastes from industrial processes e.g., sawdust, paper pulp
  • consumer waste and energy crops grown specifically for fuel production such as switchgrass.
  • Cellulosic biomass is composed of cellulose, hemicellulose and lignin, with smaller amounts of proteins, lipids (fats, waxes and oils) and ash. Roughly, two-thirds of the dry mass of cellulosic materials are present as cellulose and hemicellulose. Lignin makes up the bulk of the remaining dry mass.
  • Lignocellulosic biomass is particularly well-suited for energy applications because of its large-scale availability, low cost, and environmentally benign production.
  • many energy production and utilization cycles based on lignocellulosic biomass have near-zero greenhouse gas emissions on a life-cycle basis.
  • a process for producing a fermentation product comprises introducing biomass into a tank; introducing a microorganism into the tank; mixing the biomass and the microorganism in the tank to form a slurry; pumping the slurry from the tank to the cone bottom fermenter; allowing the microorganism to ferment the biomass in the cone bottom fermenter; and recovering one or more products of the fermentation, wherein the cone bottom fermenter has a cone-shaped bottom having an angle, measured with respect to a horizontal flat plane, in a range of from above 45 degrees to about 80 degrees.
  • the biomass and microorganism are mixed in the tank with an agitator.
  • a residence time of the slurry in the cone bottom fermenter is in a range of from about 30 minutes to about 10 hours.
  • a solids content of the biomass in weight percentage is in a range of from about 5% to about 45%.
  • the tank comprises a cone bottom tank.
  • the tank is proportionally dimensioned from about l/5th to about 1/50th a size of the cone bottom fermenter.
  • the slurry is pumped into a top portion of the cone bottom fermenter.
  • a portion of the slurry exiting the cone-shaped bottom of the cone bottom fermenter is recycled to the tank.
  • the recycled portion passes through a heat exchanger before entering the tank.
  • the slurry passes through a heat exchanger before entering the cone bottom fermenter.
  • the slurry comprises a solids content in a range of from about 5% to about 45% by weight.
  • the angle is in a range of from about 60 degrees to about
  • the angle is about 60 degrees, with respect to a horizontal flat plane.
  • the biomass comprises lignocellulosic biomass.
  • the lignocellulosic biomass comprises grass, switch grass, cord grass, rye grass, reed canary grass, mixed prairie grass, miscanthus, sugar-processing residues, sugarcane bagasse, sugarcane straw, agricultural wastes, rice straw, rice hulls, barley straw, corn cobs, cereal straw, wheat straw, canola straw, oat straw, oat hulls, corn fiber, stover, soybean stover, corn stover, forestry wastes, recycled wood pulp fiber, paper sludge, sawdust, hardwood, softwood, agave, and combinations thereof.
  • the microorganism is selected from the group consisting of yeast, bacteria, fungi, and combinations thereof.
  • the microorganism is a recombinant microorganism.
  • the microorganism produces ethanol.
  • the microorganism comprises Saccharomyces cerevisiae
  • the microorganism is a yeast.
  • the microorganism is Saccharomyces cerevisiae.
  • the microorganism is a xylose-utilizing microorganism, a glucose-utilizing microorganism, or both.
  • the microorganism expresses one or more enzymes that break down cellulose in the biomass into sugars and ferments the sugars into ethanol.
  • the enzymes are heterologous to the microorganism.
  • the fermenting of the biomass in the cone bottom fermenter occurs without the use of a mixing device in the cone bottom fermenter.
  • the fermentation product comprises ethanol.
  • the slurry further comprises one or more exogenous enzymes. [0035] In some embodiments, the slurry further comprises one or more catalysts that mimic enzymes.
  • the biomass is pretreated.
  • a system for producing a fermentation product comprising: a mixing tank configured to form a slurry comprising biomass and a microorganism; a cone bottom fermenter configured to receive the slurry, wherein the cone bottom fermenter has a cone-shaped bottom having an angle, measured with respect to a horizontal flat plane, in a range of from above 45 degrees to about 80 degrees; and a pump configured to move the slurry from the mixing tank to the cone bottom fermenter.
  • the angle is in a range of from about 60 degrees to about
  • the angle is about 60 degrees, with respect to a horizontal flat plane.
  • the cone bottom fermenter further comprises a cylindrical portion above the cone-shaped bottom and wherein a ratio of a height of the cone-shaped bottom to the cylindrical portion is in a range of from about 0.2 to about 50.
  • the mixing tank comprises a cone bottom tank.
  • the mixing tank is proportionally dimensioned in a range of from about l/5th to about l/50th a size of the cone bottom fermenter.
  • the cone bottom fermenter further comprises an inlet nozzle arranged near a top portion of the cone bottom fermenter at an angle, measured with respect to a horizontal flat plane, in a range of from about 0 degrees to about 40 degrees for introducing the slurry into the cone bottom fermenter.
  • the angle of the inlet nozzle is about 0 degrees.
  • the system is configured for the microorganism to ferment the biomass in the cone bottom fermenter without the use of a mixing device in the cone bottom fermenter.
  • the system further comprises a heat exchanger through which the slurry passes before entering the cone bottom fermenter.
  • the system further comprises a second pump configured to recycle a portion of the slurry exiting the cone-shaped bottom of the cone bottom fermenter to the mixing tank ⁇ [0048] In some embodiments, the system further comprises a second heat exchanger through which the recycled portion passes before entering the mixing tank.
  • FIG. 1 schematically illustrates an exemplary method and system of the present invention for producing a fermentation product.
  • FIG. 2 schematically illustrates an alternative exemplary method and system of the present invention for production of a fermentation product.
  • FIG. 3 illustrates the fermentation time course in a 2L agitated flat bottom laboratory fermenter.
  • FIG. 4 illustrates the fermentation time course in a 1,000 gallon cone bottom fermenter without the use of an agitator.
  • FIG. 5 illustrates the fermentation time course in a 1,000 gallon flat bottom fermenter with the use of an agitator.
  • FIG. 6 illustrates the fermentation time course in a 5,000 gallon cone bottom fermenter without the use of an agitator.
  • compositions, a mixture, a process, a method, an article, or an apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such composition, mixture, process, method, article, or apparatus.
  • “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
  • invention or “present invention” as used herein is a non-limiting term and is not intended to refer to any single embodiment of the particular invention but encompasses all possible embodiments as described in the application.
  • Biomass as used herein means biological material made by the growth of living organisms.
  • Frermentation or “fermentation process” as used herein means any process comprising a fermentation step.
  • Frermentation product as used herein means a product of a fermentation process.
  • “Fermenter” as used herein means a vessel in which fermentation occurs.
  • Mating tank as used herein means a vessel wherein mixing takes place with use of mixing device, such as, for example, an agitator.
  • the present invention provides processes and systems for producing a fermentation product. in some embodiments, biomass and a microorganism are introduced into a tank and mixed in the tank to form a slurry. The slurry is pumped to a cone bottom fermenter where the microorganism is allowed to grow and ferment the biomass into a fermentation product, such as, for example, ethanol.
  • the cone bottom fermentei can have a cone-shaped bottom having an angle in a range from above 45 degrees to about 80 degrees.
  • FIG. 1 illustrates an exemplary process and system 100 for producing a fermentation product.
  • a feed stream of biomass 102 can be fed into a mixing tank 106.
  • Biomass can be classified into three main categories: sugar, starch, and cellulose-containing plants.
  • biomass stream 102 can include sugars, including glucose and xylose, starch, cellulose-containing plants, or combinations thereof.
  • biomass stream 102 includes lignocellulosic biomass.
  • hemicellulose means the non-lignin, non-cellulose elements of lignocellulosic material, such as but not limited to hemicellulose (comprising xyloglucan, xylan, glucuronoxylan, arabinoxylan, mamian, glucomannan, and galactoglucomannan, inter alia), pectins (e.g., homogalacturonans, rhamnogalacturonan I and II, and xylogalacturonan), and proteoglycans (e.g., arabinogalactan-protein, extensin, and proline-rich proteins).
  • hemicellulose comprising xyloglucan, xylan, glucuronoxylan, arabinoxylan, mamian, glucomannan, and galactoglucomannan, inter alia
  • pectins e.g., homogalacturonans, rhamnogalacturonan I and II, and
  • lignocellulosic biomass can include, but is not limited to, woody biomass, such as recycled wood pulp fiber, sawdust, hardwood, softwood, and combinations thereof; grasses, such as switch grass, cord grass, rye grass, reed canary grass, miscanthus, mixed prairie grasses, or a combination thereof; sugar-processing residues, such as but not limited to energy cane, sugar cane bagasse; agricultural wastes, such as but not limited to cobs and corn fiber, rice straw, rice hulls, barley straw, cereal straw, wheat straw, canola straw, oat straw, oat hulls, beet pulp, palm residue, and; stover, such as but not limited to soybean stover, corn stover; and forestry wastes, such as but not limited to recycled wood pulp fiber, sawdust, hardwood (e.g., poplar, oak, maple, birch), softwood, newsprint or any combination thereof.
  • woody biomass such as recycled wood pulp fiber, sawdust, hardwood,
  • Paper sludge is also a viable feedstock for ethanol production and can be another type of lignocellulosic biomass. Paper sludge is solid residue arising from pulping and paper-making, and is typically removed from process wastewater in a primary clarifier. The size range of the substrate material varies widely and depends upon the type of substrate material used as well as the requirements and needs of a given process.
  • the lignocellulosic biomass may be prepared in such a way as to permit ease of handling in conveyors, hoppers and the like.
  • the chips obtained from commercial chippers are suitable; in the case of straw it is sometimes desirable to chop the stalks into uniform pieces about 0.5 to about 3 inches in length, and about 3 to about 5 mm in width.
  • the size of the substrate particles prior to pretreatment may range from less than a millimeter to inches in length.
  • Cellulose molecules are linear, unbranched and can have polymerization ranges from 500 to 20,000 and have a strong tendency to form inter- and intra-molecular hydrogen bonds. Bundles of cellulose molecules are thus aggregated together to form microfibrils in which highly ordered (crystalline) regions alternate with less ordered (amorphous) regions. Microfibrils make fibrils and finally cellulose fibers. As a consequence of its fibrous structure and strong hydrogen bonds, cellulose has a very high tensile strength and is insoluble in most solvents.
  • Lignocellulosic biomass can undergo pre-treatment to enhance susceptibility to hydrolysis.
  • the degradation of lignocellulosic biomass is primarily governed by its structural features because cellulose possesses a highly ordered structure and the lignin surrounding cellulose forms a physical barrier.
  • Pretreatment of lignocellulosic biomass can reduce the lignin content, reduce the order of the cellulose and increase surface area.
  • pretreatment can increase conversion yield during fermentation.
  • Pretreatment methods can be physical, chemical, physicochemical and/or biological, depending on the mode of action.
  • the various pretreatment methods that have been used to increase cellulose digestibility include, for example, ball-milling treatment, two-roll milling treatment, hammer milling treatment, colloid milling treatment, high pressure treatment, radiation treatment, pyrolysis, catalytic treatment, acid treatment, alkaline treatment, organic solvent treatment, steam treatment, heat treatment, low-pH treatment, steam explosion treatment, pulping treatment, white rot fungi treatment, steam explosion and ammonia fiber explosion, continuous hydrolysis treatment, and combinations thereof.
  • Pretreatment can be a single-stage pretreatment or a multiple-stage pretreatment (such as, two-stage pretreatment).
  • Exposure time, temperature, and pH are the additional metrics that govern the extent to which the cellulosic carbohydrate fractions cleaved during pretreatment are amenable to further enzymatic hydrolysis in subsequent biological conversion steps.
  • pretreatment of biomass stream 102 can be carried out at severities of about 3, about 3.2, about 3.5, about 3.7, about 3.9, about 4, about 4.2, about 4.5, or about 4.6.
  • pretreatment of biomass stream 102 can be carried out at severities in a range of about 3 to about 4.6, about 3 to about 4.5, about 3 to about 4.2, about 3 to about 4, about 3 to about 3.9, about 3 to about 3.7, about 3 to about 3.5, about 3 to about 3.2, about 3.2 to about 4.6, about 3.2 to about 4.5, about 3.2 to about 4.2, about 3.2 to about 4, about 3.2 to about 3.9, about 3.2 to about 3.7, about 3.2 to about 3.5, about 3.5 to about 4.6, about 3.5 to about 4.5, about 3.5 to about 4.2 about 3.5 to about 4, about 3.5 to about 3.9, about 3.5 to about 3.7, about 3.7 to about 4.6, about 3.5 to about 4.5, about 3.5 to about 4.2 about 3.5 to about
  • R 0 t exp[(T-100)/14.75] (1) wherein t is the time in minutes and T is the temperature in °C.
  • the biomass can be pretreated in a first stage, for example a low severity treatment of about 3 to about 3.8 to separate hemicellulose and cellulose.
  • the low severity treatment can be followed by a washing step to separate solubilized hemicellulose from cellulose.
  • the hemicellulose can be fed to mixing tank 106 as part of biomass stream 102 and can be broken down into 5-carbon sugars, such as xylose, through the catalytic action of xylanases which may be added as an exogenous enzyme or produced by a CBP microorganism.
  • the cellulose separated from the hemicellulose in the first stage can be pretreated in a second stage, for example a high severity treatment in the range of about 3.8 to about 4.6.
  • the cellulose can be fed to mixing tank 106 as part of biomass stream 102 and can be broken down into 6-carbon sugars, such as glucose.
  • the biomass can be pretreated in a single stage at low severity conditions to obtain hemicellulose, which can be broken down into 5-carbon sugars.
  • the biomass can be treated in a single state at high severity conditions to obtain cellulose, which can be broken down into 6-carbon sugars.
  • pretreatment temperatures can exceed 215 °C, thereby providing an aseptic or sterile feedstock.
  • the pretreated biomass can be utilized at the same rate at which it is generated. However, if the pretreated substrate is stored for a period after pretreatment before it is fermented, the pretreated substrate can be processed to maintain aseptic or sterile conditions.
  • aseptic conditioning is obtained by hot washing an aqueous suspension of the substrate at a high temperature, for example at 190 °F, followed by the addition of an acid, for example phosphoric acid, to bring the aqueous suspension of the substrate (i.e., slurry) to a low pH, for example a pH of 2.
  • the aseptic conditioning can reduce introduction of bacteria when pretreated substrate is stored at the room temperature.
  • sterile conditioning is obtained by holding a slurry of the pretreated substrate for at least about 15 minutes at about 121 °C. In some embodiments, sterile conditioning is obtained by holding a slurry of the pretreated substrate for about 3 minutes at about 134 °C. In some embodiments, the sterile conditioning is obtained by an autoclave that commonly uses steam heated to about 121 - 134 °C.
  • a feed stream 104 of fermentation microorganism can also be fed into mixing tank 106.
  • fermentation microorganisms can be selected from bacteria, fungi, yeast, or combinations thereof.
  • the microorganism can be a recombinant microorganism.
  • useful recombinant microorganisms can include Saccharomyces cerevisiae, Kluyveromyces lactis, Kluyveromyces marxianus, Pichia pastoris, Yarrowia lipolytica, Hansenula polymorpha, Phaffia rhodozyma, Candida utliis, Arxula adeninivorans, Pichia stipitis, Debaryomyces hansenii, Debaryomyces polymorphus, Schizosaccharomyces pombe, Candida albicans, Schwanniomyces occidentalis, as well as bacteria, such as, Eschirichia coli, Thermoanaerobacteium saccharolyticum, and Clostridium thermocellum.
  • the recombinant microorganism is a consolidated bioprocessing (CBP) enabling microorganism that performs hydrolysis and fermentation concurrently.
  • CBP consolidated bioprocessing
  • a combination of exogenous helper enzymes and fermentative CBP microorganisms can be used.
  • CBP is a process configuration that can perform the following transformations in a single step: (1) the production of saccharolytic enzymes (e.g., amylases, cellulases and hemicellulases); (2) the hydrolysis of carbohydrate components present in pretreated biomass to sugars; (3) the fermentation of hexose sugars (e.g., glucose, mannose, and galactose) and uronic acids; and (4) the fermentation of pentose sugars (e.g., xylose and arabinose).
  • the microorganism is a xylose-utilizing microorganism (e.g., it ferments xylose).
  • the microorganism is a glucose-utilizing microorganism (e.g., it ferments glucose). In some embodiments, the microorganism is capable of fermenting glucose and xylose to ethanol, and has demonstrated substrate range so that it may utilize other sugars or organic components to produce ethanol. In some embodiments, the microorganism expresses one or more enzymes that break down cellulose in the biomass to sugars (e.g., hydrolyze cellulose) and ferments the sugars into a fermentation product, such as, for example, ethanol, organic acids, propanols, butanols, butanediols, polyols, and/or other fermentation products.
  • a fermentation product such as, for example, ethanol, organic acids, propanols, butanols, butanediols, polyols, and/or other fermentation products.
  • a major cost in producing ethanol from cellulose is the cost of added enzymes needed to break down the cellulose to glucose.
  • CBP microorganisms secrete cellulases needed to provide sugar, as well as a pathway to convert the sugar into ethanol.
  • the use of CBP microorganisms thus reduces the cost of ethanol production and helps achieve an efficient and economic production of ethanol.
  • CBP fermentation also allows for an extended ethanol production in which fermentable substrate is released at a rate determined by the metabolism of the yeast. This is unlike a corn or sugar fermentation, or traditional cellulose hydrolysis followed by fermentation, in which glucose is present in large metabolic excess at the beginning of the fermentation, and where the fermentation system must be designed to control a biologically uncontrolled system, i.e., rapid initial fermentation of the glucose to ethanol and concomitant release of heat.
  • the CBP technology places the control point at a microbial (microscopic) level, and enables the use of simple vessel design consisting of a cone bottom and external mixing tank where slow recirculation of broth through the two vessels during the fermentation process is sufficient to control the fermentation and allow sustained ethanol production.
  • additional materials can be fed into mixing tank 106, such as, for example, media, water, inoculum, exogenous enzymes (i.e., enzymes that are not provided by the CBP microorganism), and/or one or more catalysts that mimic enzymes.
  • exogenous enzymes are added to mixing tank 106 to aid in hydrolysis of the biomass.
  • the microorganism expresses the enzymes, either endogenously and/or heterologously.
  • Suitable exogenous enzymes can include, for example, cellulases, endoglucanases, exoglucanases, cellobiohydrolases, ⁇ - glucosidases, xylanases, endoxylanases, exoxylanases, ⁇ -xylosidases, arabinoxylanases, mannases, glactases, pectinases, glucuronidases, amylases, a-amylases, ⁇ -amylases, glucoamylases, a-glucosidases, isoamylases, proteases, esterases, nucleases, and mixtures thereof.
  • a particle size of the biomass in the slurry ranges from about 10 microns to greater than about 3,000 microns.
  • a particle size of the biomass in the slurry is about 10 microns, about 100 microns, about 500 microns, about 1,000 microns, about 2,000 microns, about 3,000 microns, and/or mixtures thereof.
  • a size of the microorganism ranges from about 2 microns to about 20 microns.
  • mixing of biomass feed stream 102 and microorganism feed stream 104 can be accomplished through the use of conventional agitators.
  • Agitators typically include an electric motor, a gearbox for speed reduction, a shaft for transmitting rotational motion to various portions of a vessel, and impellers.
  • the impellers can induce axial flow, radial flow, or combinations thereof in the fluid which they contact.
  • mixing of biomass feed stream 102 and microorganism feed stream 104 occurs as a result of rotational motion of liquid in mixing tank 106.
  • the rotational motion can be caused by liquid (e.g., feed streams 102 and 104) flowing into mixing tank 106 in an off-center direction, on a path which does not intersect with a centerline of mixing tank 106.
  • mixing in mixing tank 106 can occur as a result of the rotational motion without the use of a mixing device (e.g., an agitator).
  • mixing in mixing tank 106 can occur as a result of a combination of the rotational motion and the use of a mixing device.
  • mixing tank 106 can be made from conventional materials, such as, for example, stainless steel, fiber reinforced polymer, metal matrix composite, ceramic matrix composite, thermoplastic matrix composite, metal, epoxy lined carbon steel, plastic lined carbon steel, plastic, fiberglass, glass lined carbon steel, metal alloys based on iron, nonferrous metals in pure or alloy forms, plastic lined concrete, and/or metal lined concrete.
  • conventional materials such as, for example, stainless steel, fiber reinforced polymer, metal matrix composite, ceramic matrix composite, thermoplastic matrix composite, metal, epoxy lined carbon steel, plastic lined carbon steel, plastic, fiberglass, glass lined carbon steel, metal alloys based on iron, nonferrous metals in pure or alloy forms, plastic lined concrete, and/or metal lined concrete.
  • a pipe leading to the fermenter 110 is sufficiently large to allow for the mixing of the biomass feed stream 102 and the microorganism feed stream 104 in the pipe so that no mixing tank 106 is needed.
  • the pipe has a diameter in a range of about 3 inches to about 2 feet.
  • Slurry stream 108 exits mixing tank 106 and enters fermenter 110.
  • slurry stream 108 can have a solids content, as a percentage of weight, of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%), or about 45%.
  • slurry stream 108 can have a solids content, as a percentage of weight, in a range from about 5% to about 45%, about 5% to about 40%, about 5% to about 35%, about 5% to about 30%, about 5% to about 25%, about 5% to about 20%, about 5% to about 15%, about 5% to about 10%, 10% to about 45%, about 10% to about 40%, about 10% to about 35%, about 10% to about 30%, about 10% to about 25%, about 10% to about 20%, about 10% to about 15%, 15% to about 45%, about 15% to about 40%, about 15% to about 35%, about 15% to about 30%, about 15% to about 25%, about 15% to about 20%, 20% to about 45%, about 20% to about 40%, about 20% to about 35%, about 20% to about 30%, about 20% to about 25%, 25% to about 45%, about 25% to about 40%, about 25% to about 35%, about 25% to about 30%, about 30% to about 45%, about 30% to about 35%, 35% to about 45%, about 35% to about 45%, about 35% to about
  • pump 1 12 moves slurry stream 108 to fermenter 1 10.
  • Pump 1 12 can be, for example, a centrifugal-type pump or a reciprocating-type pump.
  • the hold-up volume is approximately 5 gallons and the head against which pump 1 12 must move slurry stream 108 is within a range from less than about 15 feet to as much as about 1 10 feet of liquid.
  • the flow rate through pump 1 12 can be within a range bounded by 0.1 turnovers per hour of fermenter 1 10 and about 5 turnovers per hour.
  • the flow rate through pump 112 can be within a range of from about 100 gallons/minute to about 9,000 gallons/minute.
  • the flow rate of the pump, and therefore the pump size depends on the turn over rate (the reciprocal of residence time) and fermentation volume, and can be adjusted accordingly for optimization of the fermentation process.
  • liquid slurry stream 108 can pass through a heat exchanger
  • heat exchanger 1 14 can cool slurry stream 108 to maintain the temperature in an active temperature range of the microorganism.
  • heat exchanger 1 14 is positioned just before the inlet to fermenter 1 10.
  • heat exchanger 1 14 is designed to control the temperature of fermenter 1 10 within a range of +/- 2 °C based on the optimal temperature needed for the microorganism used.
  • heat exchanger 1 14 controls the temperature at about 20°C, about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, or about 60°C. In some embodiments, heat exchanger 1 14 controls the temperature in a range of from about 20°C to about 60°C, about 20°C to about 55°C, about 20°C to 50°C, about 20°C to about 45°C, about 20°C to about 40°C, about 20°C to about 35°C, about 20°C to about 30°C, about 20°C to about 25°C, 25°C to about 60°C, about 25°C to about 55°C, about 25°C to 50°C, about 25°C to about 45°C, about 25°C to about 40°C, about 25°C to about 35°C, about 25°C to about 30°C, 30°C to about 60°C, about 30°C to about 55°C, about 30°C to 50°C, about
  • heat exchanger 1 14 can be, for example, any of the following types: shell and tube, tube in tube, finned tube, scraped-surface tube, wide-gap plate and frame, spiral, and/or combinations thereof.
  • a fermentation process includes, without limitation, fermentation processes used to produce alcohols, organic acids, ketones, amino acids, gases, antibiotics, enzymes, vitamins and hormones. Fermentation processes also include fermentation processes used in the consumable alcohol industry, dairy industry, leather industry and tobacco industry. The product of the fermentation process is referred to herein as a fermentation product.
  • slurry stream 108 can contain no exogenous enzyme, or enzyme can be added to give slurry concentrations in a range of from about 0.05 grams/liter to about 5 grams/liter within the fermenter.
  • a concentration of the microorganism in fermenter 1 10 can be up to about 100 grams/liter.
  • fermenter 1 10 can be a cone bottom fermenter that has a cone-shaped bottom portion 1 16 and a cylindrical-shaped top portion 1 1 8.
  • cone-shaped bottom portion 1 16 can be an accentric cone shape.
  • cone-shaped bottom portion 116 can be a concentric cone shape.
  • the slurry is shear thinning, meaning that slurry is viscous, but will flow upon being mixed.
  • the angle of cone-shaped bottom portion 1 16 is important in order to ensure that the slurry will flow down the slope of cone-shaped bottom portion 116 and not just remain stuck to the slope of cone-shaped bottom portion 116. If the slurry does not flow down the slope of cone-shaped bottom portion 1 16, then fermenter 1 10 becomes difficult to clean and outlets of fermenter 1 10 located in cone-shaped bottom portion 116 can become clogged.
  • cone-shaped bottom portion 1 16 has an angle a of about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, or about 80 degrees. In some embodiments, in order to avoid the problems discussed above, cone-shaped bottom portion 1 16 has an angle a in a range from above 45 degrees to about 80 degrees, above 45 degrees to about 75 degrees, above 45 degrees to about 70 degrees, above 45 degrees to about 65 degrees, above 45 degrees to about 60 degrees, above 45 degrees to about 55 degrees, above 45 degrees to about 50 degrees, about 50 degrees to about 80 degrees, about 50 degrees to about 75 degrees, about 50 degrees to about 70 degrees, about 50 degrees to about 65 degrees, about 50 degrees to about 60 degrees, about 50 degrees to about 55 degrees, about 55 degrees to about 80 degrees, about 55 degrees to about 75 degrees, about 55 degrees to about 70 degrees, about 55 degrees to about 65 degrees, about 55 degrees to about 60 degrees, about 60 degrees to about 80 degrees, about 60 degrees to about 75 degrees, about 60 degrees to about 60 degrees to about 80 degrees, about 60 degrees to about
  • a ratio of the height of cone-shaped bottom portion 1 16 to the height of cylindrical-shape top portion 1 18 can be in a range of from about 0.2 to about 50, about 0.2 to about 40, about 0.2 to about 30, about 0.2 to about 20, about 0.2 to about 10, about 0.2 to about 5, about 0.2 to about 1, about 1 to about 50, about 1 to about 40, about 1 to about 30, about 1 to about 20, about 1 to about 10, about 1 to about 5, about 5 to about 50, about 5 to about 40, about 5 to about 30, about 5 to about 20, about 5 to about 10, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 50, about 30 to about 40, or about 40 to about 50.
  • fermenter 110 can be made from stainless steel, fiber reinforced polymer, metal matrix composite, ceramic matrix composite, thermoplastic matrix composite, metal, epoxy lined carbon steel, plastic lined carbon steel, plastic, and/or fiberglass.
  • fermenter 1 10 is sized to have a volume of about 1,000 gallons, about 5,000 gallons, about 10,000 gallons, about 50,000 gallons, about 100,000 gallons, about 200,000 gallons, about 300,000 gallons, about 400,000 gallons, about 500,000 gallons, about 750,000 gallons, or about 1,000,000 gallons.
  • fermenter 1 10 has a volume from about 1 ,000 gallons to about 1,000,000 gallons, about 1 ,000 gallons to about 750,000 gallons, about 1,000 gallons to about 500,000 gallons, about 1,000 gallons to about 400,000 gallons, about 1,000 gallons to about 300,000 gallons, about 1 ,000 gallons to about 200,000 gallons, about 1,000 gallons to about 100,000 gallons, about 1,000 gallons to about 50,000 gallons, about 1 ,000 gallons to about 10,000 gallons, about 1,000 to about 5,000 gallons, about 5,000 gallons to about 1,000,000 gallons, about 5,000 gallons to about 750,000 gallons, about 5,000 gallons to about 500,000 gallons, about 5,000 gallons to about 400,000 gallons, about 5,000 gallons to about 300,000 gallons, about 5,000 gallons to about 200,000 gallons, about 5,000 gallons to about 100,000 gallons, about 5,000 gallons, g
  • mixing tank 106 is smaller than fermenter 1 10.
  • the larger the amount of biomass and microorganisms to be mixed the more energy that is required to produce a slurry. Initially, the viscosity of the slurry peaks when hydrolysis of the biomass starts and then decreases over time. Thus, the larger the amount of biomass being hydrolyzed the larger the viscosity of the slurry during the initial phases of the fermentation until sufficient hydrolysis is achieved so that a noticeable decrease in viscosity occurs.
  • the larger the viscosity of the slurry the more energy that is needed to run an agitator and the larger the agitator needed to mix/agitate the slurry.
  • the agitator needs to be designed for the maximal energy input needed to mix the slurry during the peak viscosity time period.
  • mixing with a mixing device e.g., an agitator
  • fermenting in a single vessel can be too expensive in terms of capital expenditure (e.g., the cost of the mixing device) and the energy expenditure (e.g., the amount of energy needed to run the mixing device).
  • capital expenditure e.g., the cost of the mixing device
  • the energy expenditure e.g., the amount of energy needed to run the mixing device.
  • fermenter 1 10 does not have a mixing device (e.g, an agitator). In some embodiments fermenter 1 10 does not have any internal moving parts.
  • a mixing tank 106 that is smaller than fermenter 1 10
  • larger quantities of biomass slurry can be fermented in fermenter 1 10 without the associated higher cost of mixing with a mixing device and fermenting the larger fermenter 110.
  • the combination of mixing tank 106 and fermenter 1 10 results in a reduction in net greenhouse gases during the fermentation process and minimizes the carbon footprint of the fermentation process.
  • the larger the amount of biomass and microorganisms being mixed the larger the amount of heat that is generated.
  • Heat exchanger 1 14 must be designed to accommodate the peak heat load.
  • the combination of mixing tank 106 and fermenter 110 reduces the amount of peak heat load generated, thereby reducing the cost of heat exchanger 1 14 and providing further reduction in the net greenhouse gases and carbon footprint of the fermentation process.
  • mixing tank 106 can also have a cone-shaped bottom portion and a cylindrical-shaped top portion.
  • the cone-shaped bottom portion can be an accentric cone shape.
  • the cone-shaped bottom portion 116 can be a concentric cone shape.
  • the dimensions of mixing tank 106 are proportional to the dimensions of fermenter 110.
  • mixing tank 106 is proportionally dimensioned to be about l/5 th , about l/10 th , about l/20 th , about l/30 th , about l/40 th , or about l/50 th the size of fermenter 1 10.
  • mixing tank 106 is proportionally dimensions to be in a range of from about l/5 th to about l/50 th , about l/5 th to about l/40 th , about l/5 th to about l/30 th , about l/5 th to about l/20 th , about l/5 th to about l/10 th , about l/10 th to about l/50 th , about 1/10 th to about l/40 th , about 1/10 th to about l/30 th , about 1/10 th to about l/20 th , about l/20 th to about l/50 th , about l/20 th to about l/40 th , about l/20 th to about l/30 th , about l/30 th to about l/50 th , about l/20 th to about l/40 th , about l/20 th to about l/30 th , about l
  • Residence time of slurry stream 108 inside fermenter 1 10 is the amount of time slurry stream 108 spends insider fermenter 1 10 from the time it enters fermenter 1 10 until the time it leaves fermenter 1 10.
  • the number of tank turn overs per hour can be calculated by taking the reciprocal of the residence time.
  • residence time is dependent upon the microorganism and/or the enzymes used.
  • the enzyme has the smallest diffusion constant of the water soluble contents of fermenter 1 10, which permits for a longer residence time.
  • the diffusion constant of the enzyme can be in a range of from about 10 "6 cm 2 /sec about 10 "7 cm 2 /sec.
  • the microorganism in order to make use of the potential maximum residence time provided by the enzyme having a small diffusion constant, can be chosen based on its ability to stay active (e.g., to hydrolyze and/or ferment) for longer periods of time in a controlled environment.
  • the residence time (or the tank turn over rate, which is the reciprocal of residence time), depends on the pump size and fermentation volume, and can be adjusted accordingly for optimization of the fermentation process.
  • a residence time of slurry stream 108 inside fermenter 1 10 can be about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, or about 10 hours.
  • a residence time of slurry stream 108 inside fermenter 1 10 can be in a range of from about 30 minutes to about 10 hours, about 30 minutes to about 9 hours, about 30 minutes to about 8 hours, about 30 minutes to about 7 hours, about 30 minutes to about 6 hours, about 30 minutes to about 5 hours, about 30 minutes to about 4 hours, about 30 minutes to about 3 hours, about 30 minutes to about 2 hours, about 30 minutes to about 1 hour, about 1 hour to about 10 hours, about 1 hour to about 9 hours, about 1 hour to about 8 hours, about 1 hour to about 7 hours, about 1 hour to about 6 hours, about 1 hour to about 5 hours, about 1 hour to about 4 hours, about 1 hour to about 3 hours, about 1 hour to about 2 hours, about 2 hours to about 10 hours, about 2 hours to about 9 hours, about 2 hours to about 8 hours, about 2 hours to about 7 hours, about 2 hours to about 6 hours, about 2 hours to about 5 hours, about 2 hours to about 4 hours, about 2 hours to about 3 hours, about 3 hours to about 10 hours, about 3
  • slurry stream 108 is pumped into a top portion of fermenter
  • fermenter 1 10 has one or more inlet nozzles through which slurry stream 108 enters fermenter 1 10.
  • a plurality of inlet nozzles can be arranged in a horizontal plane of fermenter 110.
  • the inlet nozzle(s) can be arranged at an angle to move slurry stream 108 away for the walls of fermenter 1 10 and induce a circular mixing pattern in fermenter 110.
  • the angle of the inlet nozzle(s) can be measured between a surface of the inlet nozzle(s) and a horizontal flat plane.
  • the angle of the inlet nozzle(s) can be about 0 degrees, 10 degrees, about 20 degrees, about 30 degrees, or about 40 degrees. In some embodiments, the angle of the inlet nozzle(s) can be in a range of from about 0 degrees to about 40 degrees, about 0 degrees to about 30 degrees, about 0 degrees to about 20 degrees, about 0 degrees to about 10 degrees, about 10 degrees to about 40 degrees, about 10 degrees to about 30 degrees, about 10 degrees to about 20 degrees, about 20 degrees to about 40 degrees, about 20 degrees to about 30 degrees, or about 30 degrees to about 40 degrees.
  • slurry stream 108 into fermenter 1 10 through a one or more inlet nozzles positioned at an angle establishes a swirling motion inside fermenter 1 10 that mixes the contents of fermenter 110.
  • the microorganisms generate carbon dioxide, and the carbon dioxide bubbles provide some mixing of the contents of fermenter 1 10.
  • mixing occurs within fermenter 1 10.
  • a stream 120 exits fermenter 1 10 containing the fermentation product, for example, ethanol, and the remainder of the slurry.
  • the fermentation product can be recovered from stream 120 through conventional means (not shown) and the remainder of the contents of stream 120 (e.g., microorganism, unconverted biomass, unfermented sugars, etc.) can be recycled to mixing tank 106.
  • a pump 122 is used to move the recyclable contents of stream 120 back to mixing tank 106.
  • pump 122 can be the same as pump 1 12.
  • the recyclable contents of stream 120 can pass through a heat exchanger 124 before entering mixing tank 106.
  • heat exchanger 124 can be the same as heat exchanger 114.
  • the recyclable contents of stream 120 can include the carbon dioxide generated by the microorganism.
  • a rate of carbon dioxide generation is in a range of from less than about 0.05 volumes of gas per volume of fermentation broth per hour (vvh) to about 0.3 vvh.
  • Carbon dioxide can dissolve in the fermentation broth and form carbonic acid, which can create foaming when the acid is released as carbon dioxide when slurry from fermenter 1 10 is pumped into mixing tank 106.
  • the contents at the bottom of fermenter 1 10 are under a pressure in a range of from about 1 bar to about 3 bar as a result of the height of liquid (i.e., the liquid head) in fermenter 1 10, which is determined by the height of fermenter 1 10.
  • recycling carbon dioxide as carbonic acid back to mixing tank 106 prevents buildup of carbonic acid in fermenter 1 10 and advantageously permits degassing and defoaming to occur in mixing tank 106 in an incremental manner.
  • fermenter 1 10 and all streams entering fermenter 1 10 are kept sterile in order to avoid contaminants.
  • the pH of the contents of fermenter 1 10 is maintained according to optimal ranges for the microorganism used. In some embodiments, the pH of the contents of fermenter 1 10 is maintained at about 4, about 4.5, about 5, about 5.5, or about 6, In some embodiments, the pH of the contents of fermenter 1 10 is maintained in a range of about 4 to about 6, about 4 to about 5.5, about 4 to about 5, about 4 to about 4,5, about 4.5 to about 6, about 4.5 to about 5.5, about 4.5 to about 5, about 5 to about 6, about 5 to about 5.5, or about 5.5 to about 6.
  • the recyclable contents of stream 120 exiting fermenter 1 10 can be split into a stream 126 that is recycled back to mixing tank 106 and a stream 128 that is recycled back to fermenter 1 10.
  • the split into streams 126 and 128 occurs after heat exchanger 124.
  • the split can occur before heat exchanger 124 and each stream 126 and 128 can pass through a separate heat exchanger.
  • stream 128 can enter a top portion of fermenter 1 10 (e.g., a top portion of cylindrical-shaped top portion 1 18).
  • stream 128 enters fermenter through an inlet nozzle positioned at an angle as discussed above.
  • the flow of streams 128 and 108 into different portions of fermenter 1 10 can create a cross flow tha increases mixing in fermenter 110.
  • a cross flow can also be created by having stream 108 enter fermenter 1 10 through a top portion of fermenter 1 10 (as shown in FIG. 1) and having stream 128 enter through a bottom portion of fermenter 1 10 (not shown).
  • yeast strain Ml 873 described in International Appl. No.
  • Table 1 Data for calculation of the specific production rates of ethanol, C0 2 and heat, are summarized in Table 1.
  • the data in Table 1 were based on runs carried out in a 2L, flat bottom, agitated fermenter with pretreated hardwood feedstock MS 887 (2 stage pretreated solids) for which the fermentation time course is shown in FIG. 3. There was 1L of fermentation broth in the 2L fermenter.
  • FIG. 3 illustrates the concentration of ethanol, glycerol, lactic acid, and acetic acid over the time course of the fermentation.
  • Example 1 The fermentation of Example 1 was run again in a 1,000 gallon cone bottom fermenter without the use of an agitator and in a 1,000 gallon traditional (i.e., flat bottom) fermenter with the use of an agitator.
  • the 1,000 gallon cone bottom fermenter had an angle of 60 degrees as measured between the surface of the cone and a horizontal flat plane.
  • FIG. 4 illustrates the concentration of ethanol and lactic acid produced over the time course of the fermentation in the 1 ,000 gallon cone bottom fermenter without the use of an agitator.
  • the feed time was 48 hours.
  • FIG. 5 illustrates the concentration of ethanol and lactic acid produced over the time course of the fermentation in the 1,000 gallon traditional fermenter with the use of an agitator.
  • the feed time was 36 hours.
  • Example 1 Mixing achieved in a small scale fermenter, such as in Example 1 , is often not directly scalable to larger fermenters, due to the intensity that would require unrealistic power inputs at a large scale.
  • FIG. 3 a comparison of the results in Example 1 shown in FIG. 3 to (a) results from the 1,000 gallon cone bottom fermenter (FIG. 4) and (b) results from the 1,000 gallon traditional (e.g., flat bottom) agitated fermenter (FIG. 5) show similar results between the laboratory agitated 2L fermenter and (a) the 1,000 gallon cone bottom fermenter and (b) the 1 ,000 gallon traditional agitated fermenter.
  • PCT/US201 1/039192 filed June 3, 2011 was tested in a series of runs carried out in a 1 ,000 gallon epoxy-lined cone bottom fermenter.
  • the feedstock was hardwood pretreated in a single stage at a severity of 4.4 and washed.
  • Enzymes were loaded at a chip basis of 3.5 to 3.8 mg protein per g of solid and a washed pretreated basis of about 5 mg protein per g of solid.
  • Two fermentation runs were made at three tank turnovers (TTO) per hour.
  • TTO tank turnovers
  • the fermentation conditions and ethanol titers are summarized in Table 2 below. Table 2: Ethanol Titers for Three Tank Turnovers per Hour in a 1,000 Gallon Cone
  • TTO tank turnovers
  • TTO tank turnover
  • yeast strain Ml 873 described in International Appl. No.
  • FIG. 6 illustrates the concentration of ethanol, lactic acid, and acetic acid over the time course of the fermentation on the left side of the graph.
  • Fig. 6 also illustrates the cumulative mass (on a dry basis) of washed pretreated total solids fed to the fermenter over the time course of the fermentation on the right side of the graph.

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Abstract

La présente invention concerne un procédé et un système pour produire un produit de fermentation, tel que l'éthanol, qui comprend l'introduction de biomasse et d'un micro-organisme dans une cuve de mélange, le mélange de la biomasse et du micro-organisme dans la cuve de mélange pour former une suspension concentrée, le pompage de la suspension concentrée dans un fermenteur à base conique, et laisser le micro-organisme fermenter la biomasse en un produit de fermentation. Le fermenteur à base conique peut avoir une base en forme de cône ayant un angle dans une plage de plus de 45 degrés à environ 80 degrés.
PCT/US2012/047546 2011-07-21 2012-07-20 Procédé et système pour produire un produit de fermentation utilisant un fermenteur à base conique WO2013013126A1 (fr)

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WO2016066752A1 (fr) * 2014-10-29 2016-05-06 Cambi Technology As Procédé et dispositif pour le traitement de biomasse et de déchets organiques
WO2019204891A1 (fr) * 2018-04-23 2019-10-31 Perandin Moreira Alexander Équipements et procédé optimisé pour la fermentation de bières par lots avec levure immobilisée

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US20090286295A1 (en) * 2008-04-30 2009-11-19 Xyleco, Inc. Processing biomass
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US6168949B1 (en) * 1995-12-21 2001-01-02 Karl Rubenberger Bioreactor with vortex mixing chamber
US20070175825A1 (en) * 2004-05-18 2007-08-02 Biomass Processing Technology, Inc. System for the treating biomaterial waste streams
US20090286295A1 (en) * 2008-04-30 2009-11-19 Xyleco, Inc. Processing biomass
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Cited By (7)

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Publication number Priority date Publication date Assignee Title
WO2016066752A1 (fr) * 2014-10-29 2016-05-06 Cambi Technology As Procédé et dispositif pour le traitement de biomasse et de déchets organiques
CN107002100A (zh) * 2014-10-29 2017-08-01 坎比科技公司 处理生物质和有机废物的方法和装置
JP2017534451A (ja) * 2014-10-29 2017-11-24 キャンビ・テクノロジー・アクシェルスカブＣａｍｂｉ Ｔｅｃｈｎｏｌｏｇｙ Ａｓ バイオマスおよび有機性廃棄物を処理する方法および装置
AU2015340594B2 (en) * 2014-10-29 2018-04-12 Cambi Technology As Method and device for treating biomass and organic waste
EA029554B1 (ru) * 2014-10-29 2018-04-30 Камби Текнолоджи Ас Способ и устройство для обработки биомассы и органических отходов
US10214751B2 (en) 2014-10-29 2019-02-26 Cambi Technology As Method and device for treating biomass and organic waste
WO2019204891A1 (fr) * 2018-04-23 2019-10-31 Perandin Moreira Alexander Équipements et procédé optimisé pour la fermentation de bières par lots avec levure immobilisée

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